Operating Instructions: Sugar Mill Drive Gear Box Flender Duored SVVL 700

Operating Instructions
Customer M/s Siemens Mexico
Customer
Purchase Order 4800389025 dt.28.04.2017
No.
Project Dainsa
Siemens Order
3005260862 dated 19.05.2017
No.
Year of
2017
manufacture
SUGAR MILL DRIVE GEAR BOX
FLENDER DUORED SVVL 700
Siemens Ltd,309/2,‘A‘ Block 100,Chettipedu Village Datum/Date Name Abt./Dept.

Thandalam Post, Chennai.602105, India. 2017-12-08 PSK SEO
Page 1
SVVL
Documents / Type XXXX
Operating Instructions Index Size XXX 700
Please quote in correspondence : TD 3005260862-10
Technical data TD 3005260862 4

Drive
Dimension Drawing A5E40790760A 5
Operating Instructions BA 5020 en 06/2010 7
Gear Unit
Spare Parts Drawing A5E43680749A 60
Spare Parts List A5E43680749 61
Dimension Drawing A5E42066165A 63
P&I Diagram A5E42066043A 64
Lubrication Unit List of Equipment (LOE) A5E42065939A 65
Operating Instructions BA 7300 EN 11/2010 73
Operating Manual 90
Globe Valve Manual 149
Gear Pump Manual 150
Electric Motor Manual 162
Duplex Filter Manual 170
Diff. Pressure Switch Manual 172
Operating Manual /
Oil Cooler Manual 180
Instruction for
other Components Pressure Gauge Manual 245
Pressure Switch Manual 247
Temperature Gauge Manual 259
Flow Switch Manual 268
Temperature Switch Manual 270
Siemens Ltd,309/2,‘A‘ Block 100,Chettipedu Village Datum/Date Name Abt./Dept.

Page 2
Drive
Siemens Ltd, 309/2,‘A‘ Block 100, Chettipedu Village Datum/Date Name Abt./Dept.
Page 3
Type XXXX SVVL
Technical Data 700
Size XXX
Please quote in correspondence : TD 3005260862-10
Order No. - Item No. : 3005260862-10

Type : SVVL
Size : 700
Design : A (LH)
Mon/Year built : Dec 2017
Code : Sugar Mill Dainsa
Prime Mover : Electric motor
Motor power : 373 kW at n1 = 1200 1/min
Actual ratio : 199.39 : 1

Input speed : 1200 1/min
Output speed : 6 1/min
Operating period : NA
Direction of rotation :
(Looking at Shaft ends)
Input drive shaft, gear unit : CCW
Output drive shaft, gear unit : CW
Weight (without Oil-filling) : 16000 Kgs (approx)
Oil quantity : 660 lit (approx)
Oil Grade / Viscosity : ISO VG 460 (Mineral Oil with EP Add.)
Lubrication Type : Forced Lubrication System
Measuring surface sound
Pressure level (LpA) : refer BA 5020
Ambient temperature : +10 ºC ... +45 ºC
Dimension Drawing : A5E40790760A
Assembly Drawing : A5E43267233A
Page 4
Digitally signed by Balasundaram
Balasundaram Shankar
DN: cn=Balasundaram Shankar,
o=Siemens,
Shankar email=shankar.balasundaram@si
emens.com
2017-12-08 Balasundaram
Released
.
Page 5
Gear Unit
Page 6
Duored-2 helicalgear unit
SDNL, SDVL, SVNL, SVVL, SFNL, SFVL
Sizes 550 to 1200
Assembly and operating instructions

BA 5020 en 06/2010
FLENDER gear units
Page 7
Technical data 1
Duored-2 helicalgear unit 2

General notes
Safety instructions 3
SDNL, SDVL, SVNL, SVVL, SFNL, SFVL
Sizes 550 to 1200 Transport and
storage 4
Technical
Assembly and operating instructions description 5
Translation of the original assembly and operating instructions
Fitting 6
Startup 7
Operation 8
Faults, causes
and remedy 9
Maintenance
and repair 10
Spare parts,
customer service 11
Declarations 12
BA 5020 en 06/2010
2 / 54 Page 8
Notes and symbols in these assembly and operating instructions
Note: The term "Assembly and operating instructions" will in the following also be shortened to "instructions"
or "manual".
Legal notes
Warning note concept
This manual comprises notes which must be observed for your personal safety and for preventing material damage.
Notes for your personal safety are marked with a warning triangle or an "Ex" symbol (when applying
Directive 94/9/EC), those only for preventing material damage with a "STOP" sign.
WARNING! Imminent explosion!
The notes indicated by this symbol are given to prevent explosion damage.
Disregarding these notes may result in serious injury or death.
WARNING! Imminent personal injury!
The notes indicated by this symbol are given to prevent personal injury.
WARNING! Imminent damage to the product!
The notes indicated by this symbol are given to prevent damage to the product.
Disregarding these notes may result in material damage.
NOTE!
The notes indicated by this symbol must be treated as general operating information.
Disregarding these notes may result in undesirable results or conditions.
WARNING! Hot surfaces!
The notes indicated by this symbol are made to prevent risk of burns due to hot surfaces
and must always be observed.
Disregarding these notes may result in light or serious injury.
Where there is more than one hazard, the warning note for whichever hazard is the most serious is always used.
If in a warning note a warning triangle is used to warn of possible personal injury, a warning of material damage may
be added to the same warning note.
Qualified personnel
The product or system to which these instructions relate may be handled only by persons qualified for the work
concerned and in accordance with the instructions relating to the work concerned, particularly the safety and
warning notes contained in those instructions. Qualified personnel must be specially trained and have the
experience necessary to recognise risks associated with these products or systems and to avoid possible hazards.
BA 5020 en 06/2010
3 / 54 Page 9
Intended use of Siemens products
Observe also the following:
Siemens products must be used only for the applications provided for in the catalogue and the relevant
technical documentation. If products and components of other makes are used, they must be
recommended or approved by Siemens. The faultfree, safe operation of the products calls for proper
transport, proper storage, erection, assembly, installation, startup, operation and maintenance. The
permissible ambient conditions must be adhered to. Notes in the relevant documentations must be
observed.
Trademarks
All designations indicated with the registered industrial property mark ® are registered trademarks of Siemens AG.
Other designations used in these instructions may be trademarks the use of which by third parties for their own
purposes may infringe holders’ rights.
Exclusion of liability
We have checked the content of the instructions for compliance with the hard and software described.
Nevertheless, variances may occur, and so we can offer no warranty for complete agreement. The information
given in these instructions is regularly checked, and any necessary corrections are included in subsequent editions.
Symbols
Earth connection point Air relief point yellow
Oilfilling point yellow Oildraining point white
Oil level red Oil level red
Connection for
Oil level red
vibrationmonitoring device
Lubrication point red Apply grease
Lifting eye Eye bolt
Do not unscrew
Alignment surface, horizontal Alignment surface, vertical
These symbols indicate the oillevel checking procedure using the oil dipstick.
These symbols indicate that the oil dipstick must always be firmly screwed in.
BA 5020 en 06/2010
4 / 54 Page 10
Contents
1. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 General technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1.1 Ambient atmosphere and ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Configurations and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.1 Gearunit versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.2 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Measuringsurface soundpressure level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2. General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Obligations of the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Special dangers and personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4. Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3 Storing the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4 Standard coating and preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4.1 Preservation in the case of Tacolab seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4.2 Interior preservation with preservative agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4.2.1 Represerving the interior of the gear unit in case of longer periods of storage . . . . . . . . . . . . . . . . 18
4.4.3 Exterior preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4.3.1 Represervation of the metallic bright exterior surfaces of the gear unit . . . . . . . . . . . . . . . . . . . . . . 18
5. Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Output configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4 Toothed components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.5 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.5.1 Combined splash and forced lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.5.2 Forced lubrication by means of separate or external oilsupply installation . . . . . . . . . . . . . . . . . . . 21
5.6 Shaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.7 Shaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.7.1 Radial shaftsealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.7.2 Taconite seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.7.3 Tacolab seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.8 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.8.1 Separate/external oilsupply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.9 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.10 Indication of oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.11 Oiltemperature monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.12 Oillevel monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.13 Bearingmonitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.13.1 Bearing monitoring by Pt 100 resistance thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.13.2 Bearing monitoring by shockpulse transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.14 Speed transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.15 Reversing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.15.1 Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
BA 5020 en 06/2010
5 / 54 Page 11
6. Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1 General information on fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3 Installation of gear unit on housing base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3.1 Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3.2 Description of installation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3.2.1 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3.2.2 Fitting on a foundation frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.2.3 Fitting on a concrete foundation by means of foundation blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.3.2.4 Fitting on a concrete foundation by means of anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.4 Couplings, clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.5 Gear unit with addon components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.6 Gear unit with heating element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.7 Gear unit with oiltemperature monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.8 Gear unit with oillevel monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.9 Bearingmonitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.10 Gear unit with speed transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.11 Gear unit with separate oilsupply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.12 Final work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.13 Screwconnection classes, tightening torques and initialtensioning forces . . . . . . . . . . . . . . . . . . 36
6.13.1 Screwconnection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.13.2 Tightening torques and initialtensioning forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7. Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1 Procedure before startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.1 Removal of preservative agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.2 Filling with lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1.3 Oillevel monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1.4 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1.5 Reversing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.2 Preparing the startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2.1 Checking procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2.1.1 Gear unit with oilsupply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2.2 Temperature measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2.3 Bearing monitoring (vibration measurement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3 Removal from service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3.1 Interior preservation during longer disuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3.1.1 Interior preservation with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3.1.2 Interior preservation with preservative agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3.1.3 Interiorpreservation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.3.2 Exterior preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.3.2.1 Exteriorpreservation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.2 Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.3 Irregularities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9. Faults, causes and remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.1 General information on faults and malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.2 Possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.3 Removal of blockages (only if reversing device available) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.3.1 Switching the reversing device on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.3.2 Switching the reversing device off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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10. Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.1 General notes on maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.1.1 General oilservice lives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.2 Description of maintenance and repair works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.2.1 Test water content of oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.2.2 Change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.2.3 Clean the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.2.4 Clean the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.2.5 Refill Taconite seals with grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.2.6 Refill Tacolab seals with grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.2.7 Check hose lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.2.8 Top up oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.2.9 Check tightness of screw connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.3 Final work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.4 General inspection of the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.5 Oilsupply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.6 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
11. Spare parts, customerservice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
11.1 Stocking spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
11.2 Spare parts and customerservice addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
12. Declarations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
12.1 Declaration of incorporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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1. Technical data
1.1 General technical data
The most important technical data are shown on the rating plate. These data and the contractual
agreements between Siemens and the customer for the gear unit determine the limits of its correct use.
①
②
③ ④
⑤ ⑥
⑦ ⑧
⑨
⑩
⑪
⑫
⑬
Fig. 1: Rating plate gear unit
① Company logo ⑧ Speed n2
② Order number, item, sequence number, ⑨ Oil data

year built (oil type, oil viscosity, oil quantity)
③ Total weight in kg ⑩ Instructions number(s)
④ Special information ⑪ Special information
⑤ Type, size *) ⑫ Manufacturer and place of manufacture
⑥ Power rating P2 in kW or output torque T2 in Nm ⑬ Country of origin
⑦ Speed n1
*) Example
S D N L 550
Size . . . . . . . . . . . . . . . . . . . . . . 550 ... 1200
Type of gear unit . . . . . . . . . . . L = with load sharing
Type of output shaft . . . . . . . . . N = Solid shaft
V = Solid shaft with square
Number of stages . . . . . . . . . . . D = 3
V = 4
F = 5
Gearunit type . . . . . . . . . . . . . . S = Helical gear unit
Data on gearunit versions, weights and measuringsurface soundpressure level of the various gearunit
types are given in items 1.2.1, 1.2.2 and 1.3.
For further technical data, please refer to the drawings in the gearunit documentation and the
orderspecific data sheet.
1.1.1 Ambient atmosphere and ambient temperature
Unless otherwise agreed by contract, the gear unit must not be exposed to harmful
environmental factors such as chemically aggressive products. By adopting various suitable
measures the gear unit may be used at ambient temperatures of between 40 °C and + 60 °C.
However, this must always be approved by Siemens.
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1.2 Configurations and weights
1.2.1 Gearunit versions
SDNL SDVL
SVNL SVVL
SFNL SFVL
Fig. 2: Gearunit types

1.2.2 Weights
For the exact weights, refer to the drawings in the gearunit documentation or the rating plate.
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1.3 Measuringsurface soundpressure level
The gear unit has a measuringsurface soundpressure level at a distance of 1 m, which can be found in
table 1.
The measurement is carried out to DIN EN ISO 9614 Part 2, using the soundintensity method.
The workplace of the operating personnel is defined as the area on the measuringsurface at a distance
of 1 metre in the vicinity of which persons may be present.
The soundpressure level applies to the warmedup gear unit at input speed n1 and output power P2 or T2
stated on the rating plate, as measurement obtained on the Siemens test bench. If several figures are
given, the highest speed and power values apply.
The measuringsurface soundpressure level includes addon lubrication units, if applicable. With
outgoing and incoming pipes, the interfaces are the flanges.
The soundpressure levels stated in the table were obtained by statistical calculation by our Quality Control
department. The gear unit can be statistically expected to comply with these soundpressure levels.
Table 1: Measuringsurface soundpressure level LpA in dB(A)
n1 Gearunit size
Type iN 1/min 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200
18 1500 - - - - - - - - - - - - - -
. 1000 81 83 84 86 - - - - - - - - - -
22.4 750 78 80 80 81 81 81 82 82 83 - - - - -
25 1500 86 86 - - - - - - - - - - - -
SDNL
. 1000 81 81 82 82 83 84 - - - - - - - -
SDVL
31.5 750 78 78 79 79 79 81 81 82 82 83 - - - -
35.5 1500 83 84 84 85 - - - - - - - - - -
. 1000 78 79 79 80 81 81 82 82 - - - - - -
50 750 75 75 76 76 77 77 78 78 79 80 - - - -
50 1500 83 84 85 86 86 87 88 - - - - - - -
. 1000 79 79 81 81 81 82 83 83 84 84 85 85 86 86
71 750 75 76 77 78 78 79 79 80 80 81 82 82 83 83
80 1500 81 81 83 83 84 84 85 85 86 - - - - -
SVNL
. 1000 76 77 78 78 79 79 80 80 81 81 82 82 83 83
SVVL
112 750 73 73 75 75 76 76 77 77 78 78 79 79 80 80
125 1500 78 79 80 81 81 82 82 83 83 84 84 85 85 -
. 1000 73 74 75 76 76 77 77 78 79 79 79 80 80 81
200 750 70 71 72 72 73 73 74 75 76 76 76 77 77 78
224 1500 77 78 78 78 79 80 81 81 82 82 83 83 83 84
. 1000 72 73 73 74 74 76 76 77 78 78 78 79 79 80
355 750 69 69 70 70 71 72 73 73 74 74 75 76 76 77
400 1500 75 75 76 76 78 78 79 79 80 80 81 82 82 83
SFNL
. 1000 70 70 71 71 72 73 74 74 75 75 76 77 77 78
SFVL
500 750 67 67 67 68 68 70 70 71 72 72 73 74 74 75
560 1500 72 72 73 73 74 75 76 76 77 77 78 79 79 80
. 1000 67 68 65 68 69 70 71 72 73 73 74 75 75 76
800 750 64 64 65 65 65 67 68 68 69 69 70 71 71 72
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2. General notes
2.1 Introduction
These instructions are an integral part of the gear unit supplied and must be kept in its vicinity for reference
at all times.
All persons carrying out work on the gear unit must have read and understood these
instructions and must adhere to them. Siemens accepts no responsibility for damage
or disruption caused by disregard of these instructions.
The "FLENDER DUORED helicalgear unit" described in these instructions has been developed for
stationary use in general engineering applications. Possible areas of use for gear units of this type include
chemical industry, iron and steel industry, conveyor equipment, crane equipment, foodstuffs industry,
cement industry and others.
The gear unit is designed only for the application specified in section 1, "Technical data". Other operating
conditions must be contractually agreed.
The gear unit has been manufactured in accordance with the state of the art and is delivered in a condition
for safe and reliable use.
The gear unit must be used and operated strictly in accordance with the conditions laid down in the contract
governing performance and supply agreed by Siemens and the customer.
The gear unit described in these instructions reflects the state of technical development at the time these
instructions went to print.
In the interest of technical progress we reserve the right to make changes to the individual assemblies and
accessories which we regard as necessary to preserve their essential characteristics and improve their
efficiency and safety.
2.2 Copyright
The copyright to these instructions is held by Siemens AG.
These instructions must not be wholly or partly reproduced for competitive purposes, used in any
unauthorised way or made available to third parties without our agreement.
Technical enquiries should be addressed to the following works or to one of our customer services:
Siemens AG
Am Industriepark 2
46562 Voerde
Tel.: +49 (0)2871 / 92‐0

Fax: +49 (0)2871 / 92‐1544
E‐mail: heavy.duty.aud@siemens.com
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3. Safety instructions
Entry to the gear unit and its addon components is not permitted!
Caution! Risk of falling!
Any changes on the part of the user are not permitted. This applies equally to safety
features designed to prevent accidental contact.
3.1 Obligations of the user

• The operator must ensure that everyone carrying out work on the gear unit has read and understood
these instructions and is adhering to them in every point in order to:
─ avoid injury or damage,
─ ensure the safety and reliability of the unit,
─ avoid disruptions and environmental damage through incorrect use.
• During transport, assembly, installation, dismantling, operation and maintenance of the unit, the
relevant safety and environmental regulations must be complied with at all times.
• The gear unit may only be operated, maintained and/or repaired by persons qualified for the work
concerned (see "Qualified personnel" on page 3 of this manual).
• The outside of the gear unit must not be cleaned with highpressure cleaning equipment.
• All work must be carried out with great care and with due regard to safety.
All work on the gear unit must be carried out only when it is not in operation.
Secure the drive unit to prevent unintentional switchon (e.g. by locking the key switch
or removing the fuses from the power supply). The addon or separate oilsupply
system must also be stopped, if installed. A notice should be attached to the start
switch stating clearly that work is in progress.
• No electrical welding work must be done at all on the drive.

The drives must not be used as an earthing point for welding operations. Toothed parts and bearings
may be irreparably damaged by welding.
• A potential equalisation in accordance with the applying regulations and directives must be carried out!
If no threaded holes for earth connection are available on the gear unit, other appropriate measures
must be taken. This work must always be done by specialist electricians.
If any inexplicable changes are noticed during operation of the gear unit, such as an
important increase in temperature or unusual noises, the drive assembly must be
switched off immediately.
Rotating and/or movable drive components must be fitted with suitable safeguards to
prevent contact.
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When the gear unit is incorporated in plant or machinery, the manufacturer of such
plant or machinery must ensure that the contents of these instructions are
incorporated in his own instructions.
• Removed safety equipment must be reinstalled prior to starting up.

• Notices attached to the gear unit, e.g. rating plate, direction arrows etc., must always be observed.
They must be kept free from dirt and paint at all times. Missing plates must be replaced.
• Screws which have been damaged during assembly or disassembly work must be replaced with new
ones of the same strength class and type.
• Spare parts must always be obtained from Siemens (refer also to section 11).
3.2 Environmental protection
• Dispose of any packing material in accordance with regulations or separate it for recycling.
• When changing oil, the used oil must be collected in suitable containers. Any pools of oil which may
have collected should be removed at once with an oilbinding agent.
• Preservative agents should be stored separately from used oil.
• Used oil, preservative agents, oilbinding agents and oilsoaked cloths must be disposed of in
accordance with environmental legislation.
• Disposal of the gear unit after its useful life:
─ Drain all the operating oil, preservative agent and/or cooling agent from the gear unit and dispose
of in accordance with regulations.
─ Depending on national regulations, gearunit components and/or addon parts may have to be
disposed of or sent for recycling separately.
3.3 Special dangers and personal protective equipment
• Depending on operating conditions, the surface of the gear unit may heat up or cool down to extreme
temperatures.
In case of hot surfaces (> 55 °C) there is a risk of burns!
In case of cold surfaces (< 0 °C) there is a risk of frost injury (pain, numbness,
frostbite)!
During oil changes there is a risk of scalding from escaping oil!
Small foreign matter such as sand, dust, etc. can get into the cover plates of the
rotating parts and be thrown back by these.
Risk of eye injury!
In addition to any generally prescribed personal safety equipment (such as safety shoes,
safety clothing, helmet) handling the gear unit requires wearing suitable safety gloves and
suitable safety glasses!
The gear unit does not comply with the requirements in Directive 94/9/EC and must
therefore, in the area of applicability of this directive, not be used in potentially
explosive areas.
Caution, serious danger!
Should the gear unit be used outside the area of applicability of Directive 94/9/EC
within potentially explosive areas, the nationally applying protective prescriptions
with regard to explosion protection must always be observed.
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4. Transport and storage
Observe the instructions in section 3, "Safety instructions"!

4.1 Scope of supply
The products supplied are listed in the despatch papers. Check immediately on receipt to ensure that all
the products listed have actually been delivered. Parts damaged and/or missing parts must be reported
to Siemens in writing immediately.
If there is any visible damage, the gear unit must not be put into operation.
4.2 Transport
When transporting our products, use only lifting and handling equipment of sufficient
loadbearing capacity!
Observe the notes regarding load distribution on the packing.
The gear unit is delivered in the fully assembled condition. Additional items are delivered separately
packaged, if applicable.
Different forms of packaging may be used, depending on the size of the unit and method of transport.
Unless otherwise agreed, the packaging complies with the HPE Packaging Guidelines.
The symbols marked on the packing must be observed at all times. These have the following meanings:
Top Fragile Keep dry Keep cool Centre of Use no hand Attach
gravity hook here
Fig. 3: Transport symbols

Transport of the gear unit must be carried out so as to avoid personal damage and
damage to the gear unit.
If, for example, the free shaft ends are knocked, this may damage the gear unit.
The gear unit must be transported using suitable equipment only. During transport the gear unit
should be left without oil filling and on the transport packing.
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Use only the 4 eyes provided to attach lifting equipment to the unit.
Handling of the gear unit by attaching it to the piping is not permitted.
The pipework must not be damaged.
Do not use the front threads at the shaft ends to attach slinging and lifting gear for
transport.
Slinging and lifting gear must be adequate for the weight of the gear unit.
Fig. 4: Attachment points

For drive units where addon parts such as motor, addon coupling etc. are mounted on the gear unit an
additional attachment point may be required because of the shift in the centre of gravity.
For a detailed illustration of the gear unit and the position of the attachment points, please refer
to the drawings of the orderspecific gearunit documentation.
4.3 Storing the gear unit

The gear unit must be stored in a sheltered place in the position of the original packaging or in the position
of use, placed on a vibrationfree, dry base, and covered over.
When temporarily storing the gear unit and any single components supplied with it,
the preservative agent should be left on them. It must not be damaged, otherwise there
is a risk of corrosion.
Do not stack gear units on top of one another.
If the gear unit is being stored out of doors, it must be particularly carefully covered,
and care must be taken that neither moisture nor foreign material can collect on the
unit. Waterlogging should be avoided.
Unless otherwise agreed by contract, the gear unit must not be exposed to harmful
environmental factors such as chemically aggressive products.
Provision for special environmental conditions during transport (e.g. transport by ship) and
storage (climate, termites, etc.) must be contractually agreed.
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4.4 Standard coating and preservation
The gear unit is provided with an interior preservative agent; the free shaft ends are painted for protection.
The characteristics of the external coat depend on the ambient conditions stipulated in the order relating
to method of transport and area of application.
The gear unit is normally delivered completely ready, with a priming and a finish coat.
Where gear units are delivered with a priming coat only, it is necessary to apply
a finishing coat in accordance with directives applying to the specific application.
The priming coat alone is not suitable to provide a sufficient longterm corrosion
protection.
Ensure that the coat is not damaged!
Any damage may cause failure of the external protective coating and corrosion.
Unless otherwise contractually agreed, the durability periods of the interior gear unit
preservation specified in table 2 or 3 will apply, provided the related requirements are adhered
to. The durability period for the exterior preservation and the related requirements can be found
in table 4.
The guarantee period starts on the date of delivery or that of the notice that the item is ready
for shipment.
In the case of a storage period other than that indicated in table 2 or 3 and in table 4, the interior preservation
must be checked and, as necessary, be repeated (see items 4.4.2.1 and 4.4.3.1).
In order to prevent damages to the bearing due to standstill it is necessary to rotate (if possible by hand)
the fastrunning shaft, irrespective of the preservation period, every 6 months as long as that the
slowrunning shaft has been rotated at least 15°. The fastrunning shaft must not be in the same position
as before rotation.
After turning the airtight space must be restored (see item 4.4.1).
This procedure must be repeated until the startup, and documented.
4.4.1 Preservation in the case of Tacolab seals
Gear units with Tacolab seals are sealed airtight after applying the standard preservation method with an
adhesive tape on the gap seal (see item 5.7.3 and/or figure 9).
The adhesive tape must not be removed before startup.
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4.4.2 Interior preservation with preservative agent
Table 2: Durability period and measures for interior preservation when using mineral oil or PAObased
synthetic oil
Duration of protection Preservative agent Special measures
bis 6 Monate None
- Close all holes in the gear unit.

Replace the air filter with the screw plug.
(Prior to startup replace screw plug
Castrol Alpha SP 220 S
with air filter.)
up to 24 months
The labyrinths on the shafts must
be sealed with adhesive strip
(prior to startup this adhesive strip must
be removed). 1)
For storage periods longer than 24 months, renew the preservative agent (see item 4.4.2.1).
1) in case of Tacolab seal only (see item 5.7.3)

Table 3: Durability period and measures for interior preservation when using PGbased synthetic oil
Duration of protection Preservative agent Special measures
bis 6 Monate None
- Close all holes in the gear unit.

Replace the air filter with the screw plug.
Special anticorrosion oil (Prior to startup replace screw plug
TRIBOL 1390 2) with air filter.)
up to 36 months
The labyrinths on the shafts must
be sealed with adhesive strip
(prior to startup this adhesive strip must
be removed). 1)
For storage periods longer than 36 months, renew the preservative agent (see item 4.4.2.1).
1) In case of Tacolab seal only (see item 5.7.3)

2) Resistant to tropical conditions and sea water; maximum ambient temperature 50 °C
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4.4.2.1 Represerving the interior of the gear unit in case of longer periods of storage
For storage periods longer than 24 months (see table 2) or 36 months (see table 3), the interior
preservation of the gear unit must be renewed. The following procedure is recommended:
• Undo and remove fastening screws on the inspection and/or assembly cover.
• Remove cover with seal from housing (seal will be used again).
• Fill the gear unit with "Castrol Alpha SP 220 S".
Filling quantity according to the gearunit dimensions (length x width x height) x 0.05
Caution! In all cases the special oil "Castrol Alpha SP 220 S" with additional
corrosionprevention features (adddition "S") must be used.
Remove any oil spillage immediately with an oilbinding agent.
• Place inspection and/or assembly cover including seal on the housing.

• Place the fastening bolts of the cover and tighten them to the specified torque (see item 6.13).
• Remove adhesive tape from the labyrinths of all shafts (in case of Tacolab seals).
To prevent damages to the bearings due to a longer standstill the fastrunning shaft
should be rotated, preferably by hand.
During this operation the slowrunning shaft must be rotated at least 15°.
• This procedure must be repeated and documented every 6 months.

• The labyrinths must again be sealed with adhesive tape after each turning (only in case of Tacolab seal,
see item 4.4.2).
When using PGbased synthetic oil the gear unit must be thoroughly flushed before
its startup (see item 10.2.2).
4.4.3 Exterior preservation

Table 4: Durability period for exterior preservation of shaft ends and other bright machined surfaces
Duration Preservative Layer

of protection agent Remarks
thickness
in case
of indoor storage Longterm waxbased preservative
up to 36 months 1) agent:
Tectyl 846 K19 approx. 50 μm resistant to seawater
in case resistant to tropical conditions
of outdoor storage (soluble with CH compounds)
up to 12 months 2)
1) The gear unit must be stored in the position of use in a sheltered place; it must be placed on
a vibrationfree, dry wooden base and covered over.
2) If the gear unit is being stored out of doors, it must be particularly carefully covered, and care must be
taken that neither moisture nor foreign material can collect on the unit. Waterlogging should be avoided.
The procedure for interior and exterior preservation treatment is described in section 7
(see items 7.3.1.3 and 7.3.2.1).
4.4.3.1 Represervation of the metallic bright exterior surfaces of the gear unit
In case of storage periods exceeding the periods specified in table 4 the exterior of the gear unit must be
represerved using the preservative agent shown in table 4.
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5. Technical description

5.1 General description
The gear unit described is a DUORED helicalgear unit developed for stationary use in general engineering
applications.
The gear unit is supplied as a three, four or fivestage helical gear unit with load sharing.
It is designed for installation in the horizontal position.
The gear unit can be operated in both directions of rotation.
The gear units are characterised by a low noise level, which is achieved by helical gears with a high contact
ratio and a sounddamping housing.
The good temperature characteristics of the gear unit are achieved by its high degree of efficiency, large
housing surface and performancerelated cooling system.
A number of shaft configurations (types and rotation directions) are possible. These are shown in the
following table as solid shafts: The arrows with the direction of rotation show the correlation between the
directions of rotation of the input and output shafts.
Table 5: Types and correlation of direction of rotation
Configuration
Type
A B G H
SDNL
SDVL
SVNL
SVVL
SFNL
SFVL
5.2 Output configuration
..N. ..V.
Solid shaft Solid shaft with
square
Fig. 5: Output types

A detailed view of the gear unit can be obtained from the drawings in the gearunit documentation.
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5.3 Housing
The housing is in two parts. The housing is rigid in design and due to its form has excellent noise and
temperature characteristics.
The housing is made of cast iron; if necessary, it may also be made of nodular cast iron or of steel.
The gearunit housing comes with the following equipment:
• Lifting eyes (adequately dimensioned for transport)
• Inspection and/or assembly cover (for oil filling and/or inspection)
• Oilsight glass (for oillevel check)
• Oildrain cock (for draining oil)
• Breather screw (for venting)
Colour codes for ventilating, oil inlet, oil level and oil drainage:
Airrelief point: yellow Oildraining point: white
Oilfilling point: yellow Lubrication point: red
Oil level: red
11 1
7
14
4
2
5 5
3
9
12
6
13
10 8
Fig. 6: Gearunit features

1 Housing 8 Oildrain cock
2 Lifting eyes 9 Rating plate
3 Cover 10 Gearunit fastening
4 Cover 11 Inspection and/or assembly cover
5 Shaft seals 12 Alignment surfaces
6 Oilsight glass 13 Alignment thread
7 Housing ventilation 14 Oil inlet
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5.4 Toothed components
The helicalgear teeth are casehardened and ground. The high quality of the teeth leads to a significant
noise reduction and ensures safe and reliable running.
Load sharing ensures that the input power introduced is shared out between two lines and transmitted to
the gear of the output shaft via the pinions of both lines. This results in dual use of the larger gear of the
output stage and permits its design using smaller dimensions.
The gears are connected with the shafts by interference fits and parallel keys or by shrink fits. These types
of joints transmit with adequate reliability the torques generated.
5.5 Lubrication
5.5.1 Combined splash and forced lubrication
Lubrication of all geared parts and of the bearings is effected by a combined splash and forced lubrication
via a motordriven pump.
The operating instructions contained in an orderspecific Annex should be observed for
operation and maintenance of the motordriven pump and associated monitoring devices.
For technical data, refer to the orderspecific list of equipment.
For an accurate illustration of the gear unit and the motor pump and associated monitoring devices, refer
to the drawings in the gearunit documentation.
5.5.2 Forced lubrication by means of separate or external oilsupply installation
Lubrication of the toothed parts and the bearings can be combined with additional cooling. It is also
possible to apply a separate or external oilsupply installation. (See item 5.8)
• External oilsupply system (fitted separately, see item 5.8.1).
In the case of gear units with oilsupply system, before starting the unit up all monitors
must be connected so as to be ready for operation.
In case of gear units with addon oilsupply

system, before starting the unit up the 0.5 bar
pressure monitor must always be To be connected
connected so as to be ready for operation. as opener or closer,
as required.
Depending on the order specification and application, the
flanged pump may be replaced with a motor pump.
When operating and servicing the components of the oilsupply system, observe the operating
instructions of the components.
For technical data, refer to the data sheet and/or the list of equipment.
5.6 Shaft bearings

All shafts are mounted in rolling bearings.
5.7 Shaft seals
Depending on requirements, radial shaftsealing rings, or Taconite or Tacolab seals are mounted at the
shaft exits to prevent oil from leaking from the housing and dirt from entering it.
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5.7.1 Radial shaftsealing rings
Radial shaftsealing rings are the standard type of seal. They are fitted preferably with an additional dust
lip to protect the actual sealing lip from external contamination.
Use in an area with much dust is not possible.
Fig. 7: Radial shaftsealing ring

5.7.2 Taconite seal
Taconite seals were specially developed for use in a dusty environment. The penetration of dust is
prevented by a combination of three seal elements (radial shaftsealing ring, lamellar seal and
greasecharged rechargeable labyrinth seal).
Fig. 8: Taconite seal

1 Radial shaftsealing ring 3 Greasecharged labyrinth seal, rechargeable
2 Lamellar seal 4 Flat grease nipple
The specified recharging intervals must be observed (see section 10, "Maintenance
and repair") for recharging the Taconite seals with grease.
5.7.3 Tacolab seal

Tacolab seals are noncontacting seals, operating wearfreely and requiring very little maintenance and
which thus ensure favourable temperature characteristics. They can be used only with additional forced
lubrication of all bearings and with reduced oil level.
The Tacolab seal is made up of two parts:
─ an oil labyrinth preventing lubricating oil from escaping
─ dust seal filled with grease, which permits the use in very dusty environments.
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4
3
2
1
Fig. 9: Tacolab seal

1 Labyrinth sealing rings 3 Greasecharged labyrinth seal, rechargeable
2 Lamellar seal 4 Flat grease nipple
The specified frequencies must be observed (see section 10, "Maintenance and
repair") for recharging the Tacolab seals with grease.
5.8 Cooling
5.8.1 Separate/external oilsupply system
It is possible to use an oilsupply system which is separately supplied by Siemens or an external system
to ensure additional cooling of the oil. This will then be connected with the forced lubrication
(see item 5.5.2).
Be sure to observe the operating instructions of the oilsupply system for operation and
maintenance.
5.9 Heating
At low temperatures it may be necessary to heat the gear oil before switching on the drive unit or even
during operation. In such cases the use of heating elements is possible. These heating elements convert
electrical energy into heat which is conducted to the surrounding oil. The heating elements are located in
protective tubes inside the housing, thus making it possible to replace them without draining off the oil.
Complete immersion of the heating elements in the oil bath must be guaranteed by adhering to the
mounting position and to the oil level.
The heating elements can be controlled by a temperature monitor which emits a signal when minimum and
maximum temperatures are reached; the signal requires amplification.
For a detailed illustration of the gear unit and the position of the addon parts, please refer to the drawings
of the gearunit documentation.
Never switch on the heating elements, unless complete immersion of the heating rod
in the oil bath is ensured. Fire hazard!
If heating elements are installed afterwards, the maximum heating capacity
(see table 6) on the outer surface of the heating element must not be exceeded.
Table 6: Specific heating output PHo as a function of the ambient temperature

PHo Ambient temperature
(W/cm²) °C
0.9 + 10 to 0
0.8 0 to - 25
0.7 - 25 to - 50
Operation and maintenance must be in accordance with the pertinent operating instructions.
For technical data, refer to the list of equipment.
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5.10 Indication of oil level
The gear unit is fitted with an oillevel indicator (oilsight glass) for visual oillevel checking at standstill.
Checking of the oil level can be carried out by looking at the MIN and MAX marks of the oilsight glass when
the oil has cooled down.
5.11 Oiltemperature monitoring
Depending on the order specification, the gear unit may be fitted with a Pt 100 resistance thermometer for
monitoring the oil temperature in the sump. In order to measure the temperatures or temperature
differences, the Pt 100 resistance thermometer should be connected to a suitable instrument provided by
the customer. The thermometer has a connection head (protection type IP 54) for the wiring.
A twoconductor circuit is provided by the manufacturer. However, the customer may fit his own three or
fourconductor circuit if required.
For control information, refer to the list of equipment.
Observe the operating instructions relating to the device in all instances.
When operating and servicing the components, observe the operating instructions relating to
the components.
5.12 Oillevel monitoring system

The gear unit can be fitted with an oillevel monitor by means of a fillinglevel limit switch. This monitoring
is designed as a standstill monitoring (gear unit stop) and checks the level of the oil before the unit is started
up. It should be wired in such a way that, when the signal "oil level too low" is given, the drive motor cannot
start and that an alarm is given. During the operation, any signal must not be bridged.
If an the oillevel monitoring device is in use, it is very important that the unit is in a horizontal position.
For operation and maintenance, always observe the operating instructions indicated in the
orderspecific appendix.
For technical data, refer to the orderspecific list of equipment.
5.13 Bearingmonitoring system

5.13.1 Bearing monitoring by Pt 100 resistance thermometer
The gear unit may be fitted with Pt 100 resistance thermometers for monitoring the bearings.
In order to measure the temperatures or temperature differences, the Pt 100 resistance thermometer
should be connected to a suitable instrument provided by the customer. The thermometer has
a connection head (protection type IP 54) for the wiring. A twoconductor circuit is provided by the
manufacturer. However, the customer may also fit a three or fourconductor circuit.
For control information, refer to the list of equipment.
Observe the operating instructions relating to the device in all instances.
the components.
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5.13.2 Bearing monitoring by shockpulse transducer
The gear unit may be fitted with measuring nipples for monitoring the bearings. These nipples are intended
for attachment of shockpulse sensors with rapidaction coupling and are located in the vicinity of the
bearings to be monitored.
5.14 Speed transmitter
An incremental speed transmitter may be mounted. Wiring and evaluation instrument should be provided
by the customer.
the components.
5.15 Reversing device
For certain requirements, the gear unit can be fitted with a reversing device. This enables reversing
a jammed driven machine (e.g. a cane mill) to be reversed at a low output speed and the blockage to be
removed.
The reversing device comprises an electric motor with hand wheel, a flexible coupling, a wormgear unit
and a clutch. It is linked to the main gear unit by means of abell housing. For the basic drivetrain
arrangement refer to figure 10.
Clutch Clutch
engaged disengaged
3
2
Fig. 10: Design of the reversing device

1 Shift lever 3 Locking bolt
2 Limit switch 4 Stop knob
It must be possible to start the reversingdrive motor only on site. The machine must
be monitored while doing so. Fast reaction can prevent damage caused by overload.
If an oillubrication system is fitted, it must be in operation while starting.
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5.15.1 Changeover
The design of the clutch ensures that the teeth engage with one another without much effort. The
auxiliarydrive side will merely twist a little during the operation. If the teeth are so positioned relative to one
another that engagement is impossible, their position can be changed by inching them or adjusting the
handwheel on the reversingdrive motor.
The changing operation must be done while the unit is at rest.
Changing causes a limit switch to be actuated.
The limit switch must ensure that the main motor cannot be started.
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6. Fitting

6.1 General information on fitting
When transporting the gear unit observe the notes in section 4.
Assembly or disassembly of the DUORED helicalgear unit must only be carried out
by trained and qualified Siemens personnel in accordance with the internal Siemens
assembly instructions and using the equipment required for such operations. The
manufacturer cannot be held liable for damage caused by incorrect assembly and
installation.
During the planning phase sufficient space must be allowed around the gear unit for later care and
maintenance work.
Free convection through the surface of the housing must be ensured by suitable measures.
Adequate lifting equipment must be available before beginning the fitting work.
During operation the unit must not be allowed to heat up through exposure to heat
from external sources such as sunlight, and suitable measures must be taken to
prevent this!
Do avoid a heat concentration!
If a temperaturemonitoring device is fitted, a warning signal must be emitted when the
maximum permitted oilsump temperature is reached. If the maximum permitted
oilsump temperature is exceeded, the drive must be shut off.
Such shutting off may cause the operator's system to stop!
The operator should ensure that no foreign bodies affect the proper function of the
gear unit (e.g. falling objects or heaping over).
No welding work must be done at all on the drive.

The drives must not be used as an earthing point for welding operations. Toothed
parts and bearings may be irreparably damaged by welding.
For fastening the information given in the dimensioned drawing and foundation plan
must be observed (see drawings in the gearunit documentation).
All the fastening points provided by the design of the unit must be used.
Screws which have been damaged during assembly or disassembly work must be
replaced with new ones of the same strength class and type.
The gear unit must be slung by the points marked (see section 4, "Transport and
storage").
To ensure proper lubrication during operation, the mounting position specified on the drawings
must always be observed.
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6.2 Unpacking
The products supplied are listed in the despatch papers. Check immediately on receipt to ensure that all
the products listed have actually been delivered. Parts damaged and/or missing parts must be reported
to Siemens in writing immediately.
The packaging must not be opened or damaged, when this is part of the preservation method!
• Remove packaging material and transporting equipment and dispose of in accordance with
regulations.
• Perform a visual check for any damage and contamination.
If there is any visible damage, the gear unit must not be put into operation. The
instructions in section 4, "Transport and storage", must be observed.
6.3 Installation of gear unit on housing base

6.3.1 Foundation
The foundation should be designed in such a way that no resonance vibrations are created and that no
vibrations are transmitted from adjacent foundations. The structure on which the unit is to be mounted must
be rigid. It must be designed according to the weight and torque, taking into account the forces acting on
the gear unit.
Careful alignment with the units on the in and output sides must be ensured. Any elastic deformation
through operating forces must be taken into consideration.
Fastening bolts or nuts must be tightened to the prescribed torque. For the correct
torque, refer to item 6.13. Bolts of the minimum strength class 10.9 must be used.
If external forces are acting upon the gear unit, it is advisable to prevent the unit from displacement by
means of lateral stops.
For dimensions, space requirement, arrangement of supply connections (e.g. with separate
oilcooling units), refer to the drawings in the gearunit documentation.
6.3.2 Description of installation work

• Remove the corrosionpreventive agent on the shafts using a suitable cleaning agent.
Do not allow the cleaning agent (e.g. benzine) to contact the shaftsealing rings.
Observe the manufacturer’s instructions for handling cleaning agents!
Ensure adequate ventilation. Do not smoke.

Danger of explosion!
• Fit and secure input and output drive elements (e.g. coupling components) on the shafts.
If these are to be heated before fitting, refer to the dimensioned drawings in the coupling documentation
for the correct joining temperatures.
Unless otherwise specified, the components may be heated inductively, with a burner, or in a furnace.
Take precautions to avoid burns from hot parts!
Wear suitable protective gloves!
Protect shaftsealing rings from damage and heating to over + 100 °C

(use heatprotective screens to protect against radiant heat.)
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The components must be pushed smartly onto the shaft up to the position specified in the orderspecific
dimensioned drawing.
Fit the coupling with the aid of suitable fitting equipment. The parts must not be driven
on by abrupt force, as this may damage the gear unit (see also item 6.4).
The shaftsealing rings and running surfaces of the shaft must not be damaged when
pulling in the coupling parts.
When installing the drives, make absolutely certain that the individual components are
accurately aligned in relation to each other. Inadmissibly large errors in the alignment
of the shaft ends to be connected due to angular and/or axial misalignments result in
premature wear and/or material damage.
Insufficiently rigid base frames or substructures can also during operation cause
a radial and/or axial misalignment, which cannot be measured when the unit is at
a standstill.
Gear units whose weight requires the use of lifting gear must be attached at the points shown
in section 4, "Transport and storage". If the gear unit is to be transported with addon parts,
additional attachment points may be required. The position of these attachment points is
shown in the order related dimensioned drawing.
6.3.2.1 Alignment
Orderspecific machined surfaces (alignment surfaces) are provided on the housing parting line for
preliminary alignment in horizontal direction. To facilitate alignment, alignment threads are provided on the
housing base.
Alignment surface:
For the exact position of the alignment surfaces please refer to the drawings of the gearunit
documentation.
For aligning the gear unit special alignment surfaces are provided on the lower part of the housing. To
facilitate gearunit alignment, alignment threads are provided on the housing base.
The alignment surfaces are for aligning the gear unit horizontally, in order to ensure correct running of the
gear unit.
The values punched into the alignment surfaces must always be observed.
1 1
2 2
Fig. 11: Alignment surfaces and alignment thread

1 Alignment surfaces 2 Alignment thread
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The final fine alignment with the assemblies on the in and output side must be carried out accurately by
the shaft axes, using:
• rulers
• spirit level
• dial gauge
• feeler gauge, etc.
Only then should the gear unit be fastened and then the alignment should be checked once again.
• Record alignment dimensions.
The report must be kept with these instructions.
The accuracy of shaft axis alignment is an important factor in determining the life span
of shafts, bearings and couplings. If possible, the deviation should be zero (exception:
ZAPEX couplings). For amongst others the special requirements for the couplings,
refer to the specific operating instructions.
Nonobservance can cause shaft rupture, resulting in serious injury or danger of life.
6.3.2.2 Fitting on a foundation frame

The foundation frame must be horizontal and plain. The gear unit must not be
excessively stressed when tensioning the fastening bolts.
The levelness of the gearunit standing surface is especially important, as the contact
pattern of the teeth and the load of the bearings depend on it and the service life of the
gear unit is affected by it.
All points on the gearunit standing surface must lie between two imaginary parallel
planes 0.1 mm per 1 m apart.
• Clean the undersurface of the gearunit base and the foundation frame.
• Using suitable lifting gear, place the gear unit on the foundation frame.
Use only the eyes provided to attach lifting equipment to the unit.
transport.
• Tighten the foundation bolts to the specified torque (see item 6.13); if necessary, use stops to prevent
displacement.
• Align the gear unit exactly with the input and output units (see item 6.3.2.1).
• Record alignment dimensions (see also item 7.2).
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6.3.2.3 Fitting on a concrete foundation by means of foundation blocks
• Hook the foundation blocks with washers and fastening bolts into the foundation fastening points on
the gearunit housing (see fig. 12).
The fastening bolts must only be tightened to the tightening torque when the concrete
has set.
1 1 Fastening bolt
2
3
2 Washer
4 3 Gearunit base
7
4 Set screw
5 8 5 Flat steel plate
9 6 Foundation
7 Final foundation height
6 8 Prepared foundation height
9 Foundation block
Fig. 12: Foundation block

• Tighten the fastening bolts so far until the housing foot lies level on the foundation block.
• Using suitable lifting gear, place the gear unit on the concrete foundation.
transport.
• Align gear unit horizontally by in and output shafts:

• Align the gear unit exactly with the input and output units (see item 6.3.2.1), with the aid of the set screws
(if available).
• If considerable forces may apply, use stops to prevent the unit from displacement.
Before pouring the concrete foundation, fill up the openings in the foundation blocks with
adequate material such as polystyrene.
• Pour concrete into the recesses for the foundation blocks.

When the concrete has set, tighten the fastening bolts of the foundation blocks to the
specified torque (see item 6.13).
The gear unit must not be excessively stressed when tensioning the fastening bolts.
• Align the gear unit exactly with the input and output units (see item 6.3.2.1).
• Record alignment dimensions, see also item 7.2.
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6.3.2.4 Fitting on a concrete foundation by means of anchor bolts
• Clean the undersurface of the gearunit base.
• Place support on the base plate in the fine grout.
• Insert anchor bolts.
• Place pressure plates in position and screw nuts on.
• Place wood under the anchor bolts so that they are about 10 mm from the upper edge of the support
(see fig. 13).
2
7
3 1 Anchor bolt
8 2 Support
3 Base plate
1
4 Pressure plate
4 5 Hexagon nut
5 6 Wood
7 Finegrout concrete
6
8 Raw foundation
Fig. 13: Anchor bolt

• Place gear unit on foundation.
transport.
• Pull anchor bolts up (for this a bolt or threaded rod can be screwed into the thread on the front face).
• Fit washer.
• Screw on hexagon nut a few turns by hand.
• Align gear unit with supports (see fig. 14).
─ The values punched into the screeds must always be observed.
─ Alignment tolerances in relation to the units on the input and output sides are to be in accordance
with the permissible angular and axial displacements of the couplings (see coupling drawings).
• Record alignment dimensions (see also item 7.2).
─ The report must be kept with these instructions.
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5
4 6 1 Anchor bolt
2 2 Support
7 3 Base plate
3 4 Washer
5 Hexagon nut
8 6 Housing base
1 7 Finegrout concrete
8 Raw foundation
Fig. 14: Anchor bolt

Prior to tensioning the anchor bolts, the finegrout concrete must have set for at least
28 days.
• Keep anchor bolts in their position by tightening the nut with your fingers.
• Place the protective sleeve.
• Place hydraulic tensioning device in position.
• Initially tension the bolts alternately (for initialtensioning forces, see item 6.13).
• Using a suitable tool, screw hexagon nuts on as far as the stop.
To ensure correct handling and adjustment of the pretensioning tool, the manufacturer’s
operating instructions must be adhered to.
• The tensioning pressures and/or the initialtensioning forces should be recorded (see also item 7.2).
6.4 Couplings, clutches

As a rule, flexible couplings or safety slip clutches are provided for the drive of the gear unit.
If rigid couplings or other in and/or output elements, which create additional radial and/or axial forces,
(e.g. gear wheels, belt pulleys, disk flywheels, hydraulic couplings) are to be used, this must be agreed by
contract.
Couplings must be balanced in accordance with the specifications in the pertinent
instructions manual!
For maintenance and operation of the couplings, refer to the specific operating instructions for
the couplings.
When installing the drives, make absolutely certain that the individual components are
accurately aligned in relation to each other. Inadmissibly large errors in the alignment
of the shaft ends to be connected due to angular and/or axial misalignments result in
premature wear and/or material damage.
Insufficiently rigid base frames or substructures can also during operation cause
a radial and/or axial misalignment, which cannot be measured when the unit is at
a standstill.
For permissible alignment errors in case of couplings supplied by Siemens, please refer to the
operating instruction manuals for the couplings.
If you use couplings manufactured by other manufacturers, ask these manufacturers which
alignment errors are permissible, stating the radial loads occurring.
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Increased systemservice life and reliability and reduced running noise can be achieved
through the least possible radial and angular misalignment.
The coupling parts may get out of alignment

• due to imprecise alignment during assembly or installation
• during operation of the system due to:
─ heat expansion,
─ shaft flexure,
─ too weak machine frames, etc.
ΔKa
ΔKw
ΔKr
Axial misalignment Angular misalignment Radial misalignment
(ΔKa) (ΔKw) (ΔKr)
Fig. 15: Possible misalignments

Alignment has to be done in two axial planes arranged perpendicularly to each other. This can be done by
means of a ruler (radial misalignment) and feeler gauge (angular misalignment), as shown in the
illustration. The aligning accuracy can be increased by using a dial gauge or a laser alignment system.
1 3
2 3
Fig. 16: Example of alignment on a flexible coupling

1 Ruler 2 Feeler gauge 3 Measuring points
The maximum permissible misalignment values are specified in the operating

instructions for the coupling; they must under no circumstances be exceeded during
operation.
Angular and radial misalignments may occur at the same time. The sum of both
misalignments must not exceed the maximum permissible value of the angular or
radial misalignment.
If you use couplings manufactured by other manufacturers, ask these manufacturers
which alignment errors are permissible, stating the radial loads occurring.
For alignment of the drive components (vertical direction), it is recommended to use packing
or foil plates underneath the mounting feet. The use of claws with set screws on the foundation
for lateral adjustment of the drive components is also advantageous.
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6.5 Gear unit with addon components
• For the technical data to the addon components, as stated in item 6.6 to 6.10, refer to the orderspecific
list of equipment.
• The electrical equipment for regulation and control must be wired in accordance with the equipment
suppliers' instructions.
• For operation and maintenance the operating instructions provided specifically for the order and the
specifications in item 5.8.1 to 5.15 must be observed.
6.6 Gear unit with heating element
• Wire the heating elements electrically.
6.7 Gear unit with oiltemperature monitoring system
• Wire resistance thermometer with evaluating instrument (to be provided by customer) electrically.
6.8 Gear unit with oillevel monitoring
• Wire the levellimit switch electrically.
• Wire oillevel monitor electrically.
6.9 Bearingmonitoring system
• Wire the resistance thermometer with evaluating device electrically (in the case of a configuration as
described in item 5.13.1). The evaluating device must be provided by the customer.
6.10 Gear unit with speed transmitter
• Wire speed transmitter electrically.
6.11 Gear unit with separate oilsupply system
• Remove the sockets and/or flanges from the suction and delivery lines prior to connecting the system.
• Fit the system to the gear unit or install it separately in accordance with the drawings supplied in the
gearunit documentation.
• The pipework must not be overstressed during the mounting procedure.
6.12 Final work
• After installation of the gear unit check all screw connections listed in table 7 for tight fit.
• Check the alignment after tightening the fastening elements (the alignment must not have been
changed).
• Check that all the devices which have been demounted for transport reasons have been refitted.
─ For this refer to the details in the data sheet, the list of equipment and the associated drawings.
• Oildrain cocks, if any, must be secured against accidental opening.
• The gear unit must be protected against falling objects.
• Protective devices for rotating parts must be checked for correct seating. Contact with rotating parts
is not permitted.
• A potential equalisation in accordance with the applying regulations and directives must be carried out!
If no threaded holes for earth connection are available on the gear unit, other appropriate measures
must be taken. This work must always be done by specialist electricians.
• Cable entries should be protected against moisture.
• Check that protective measures have been taken!
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6.13 Screwconnection classes, tightening torques and initialtensioning forces
6.13.1 Screwconnection classes
The specified screw connections are to be fastened applying the tightening torques specified in the table
below.
Table 7: Screwconnection classes
Screwconnection
Fastening of Tightening procedure
class
‐ Hydraulic tightening with mechanical screwdriver

Gear unit Torquecontrolled tightening with torque wrench,
C signalemitting torque wrench
Motor*
Tightening with precision mechanical screwdriver
with dynamic torque measuring
‐ Tightening with pulse screwdriver or impact wrench

Inspection-hole cover E without adjustment checking device
Tightening by hand, using a spanner without torque
measuring device
*) The tightening torques applying to these addon parts can be found in the instructions supplied by the
manufacturers of the parts.
6.13.2 Tightening torques and initialtensioning forces
The tightening torques apply to friction coefficients of μtotal = 0.14. The friction
coefficient μtotal = 0.14 applies here to lightly oiled steel bolts, blackannealed or phosphatised
and dry, cut mating threads in steel or cast iron. Lubricants which alter the friction coefficient
must not be used and may overload the screw connection.
Table 8: Initialtensioning forces and tightening torques for screw connections of strength classes 8.8;
10.9; 12.9 with a common friction coefficient of μtotal = 0.14
Nominal Strength Initialtensioning force Tightening torque
thread class for screwconnection classes for screwconnection classes
diameter of the bolt from table 7 from table 7
C D E C D E
d FM min. MA
mm N Nm
8.8 18000 11500 7200 44.6 38.4 34.3
M10 10.9 26400 16900 10600 65.4 56.4 50.4
12.9 30900 19800 12400 76.5 66.0 58.9
8.8 26300 16800 10500 76.7 66.1 59.0
M12 10.9 38600 24700 15400 113 97.1 86.6
12.9 45100 28900 18100 132 114 101
8.8 49300 31600 19800 186 160 143
M16 10.9 72500 46400 29000 273 235 210
12.9 85000 54400 34000 320 276 246
8.8 77000 49200 30800 364 313 280
M20 10.9 110000 70400 44000 520 450 400
12.9 129000 82400 51500 609 525 468
8.8 109000 69600 43500 614 530 470
M24 10.9 155000 99200 62000 875 755 675
12.9 181000 116000 72500 1020 880 790
8.8 170000 109000 68000 1210 1040 930
M30 10.9 243000 155000 97000 1720 1480 1330
12.9 284000 182000 114000 2010 1740 1550
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Nominal Strength Initialtensioning force Tightening torque
thread class for screwconnection classes for screwconnection classes
diameter of the bolt from table 7 from table 7
C D E C D E
d FM min. MA
mm N Nm
8.8 246000 157000 98300 2080 1790 1600
M36 10.9 350000 224000 140000 2960 2550 2280
12.9 409000 262000 164000 3460 2980 2670
8.8 331000 212000 132000 3260 2810 2510
M42 10.9 471000 301000 188000 4640 4000 3750
12.9 551000 352000 220000 5430 4680 4180
8.8 421000 269000 168000 4750 4090 3650
M48 10.9 599000 383000 240000 6760 5820 5200
12.9 700000 448000 280000 7900 6810 6080
8.8 568000 363000 227000 7430 6400 5710
M56 10.9 806000 516000 323000 10500 9090 8120
12.9 944000 604000 378000 12300 10600 9500
8.8 744000 476000 298000 11000 9480 8460
M64 10.9 1060000 676000 423000 15600 13500 12000
12.9 1240000 792000 495000 18300 15800 14100
8.8 944000 604000 378000 15500 13400 11900
M72x6 10.9 1340000 856000 535000 22000 18900 16900
12.9 1570000 1000000 628000 25800 22200 19800
8.8 1190000 760000 475000 21500 18500 16500
M80x6 10.9 1690000 1100000 675000 30500 26400 23400
12.9 1980000 1360000 790000 35700 31400 27400
8.8 1510000 968000 605000 30600 26300 23500
M90x6 10.9 2150000 1380000 860000 43500 37500 33400
12.9 2520000 1600000 1010000 51000 43800 39200
8.8 1880000 1200000 750000 42100 36200 32300
M100x6 10.9 2670000 1710000 1070000 60000 51600 46100
12.9 3130000 2000000 1250000 70000 60400 53900
Damaged bolts must be replaced with new bolts of the same type and strength class.
BA 5020 en 06/2010
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7. Startup
The gear unit must not be started up, if the required instructions are not available.
7.1 Procedure before startup

7.1.1 Removal of preservative agent
Before restarting the gear unit the screw plug (if fitted) must be replaced with the
breather screw or the air filter.
Remove adhesive tape from the labyrinths (if present) (in case of Tacolab seals only,
see item 4.4.1).
The location of the oildraining points is marked by an appropriate symbol in the dimensioned drawing in
the gearunit documentation.
Oildraining point:
• Place suitable containers under the oildraining points.

• Unscrew screw plug and open oildrain cock.
• Remove remaining preservative agent and/or runningin oil from the gear unit using a suitable
container.
• Dispose of remaining preservative agent and/or runningin oil in accordance with regulations.
The oil must not come into contact with the skin (e.g. the operator’s hands).
The safety notes on the data sheets for the oil used must be observed here!
• Close the oildrain cock.

• Screw in screw plugs into the oildrain cocks again.
3 5
Fig. 17: Oil inlet/oil drain gear unit

1 Inspection and/or assembly cover 4 Oildrain cock with screw plug
2 Oilsight glass 5 Breather screw
3 Oil inlet or air filter (screw plug)
BA 5020 en 06/2010
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7.1.2 Filling with lubricant
• Visual check of the interior parts for corrosion.
If corrosion is found, contact the Siemens customer service.
Using a filter (filter fineness 25 μm), fill the gear unit with fresh oil up to the upper mark
on the oilsight glass.
The quality of the oil used must meet the requirements of the separately supplied BA 7300
operating instructions, otherwise the guarantee given by Siemens will lapse. We urgently
recommend using one of the oils listed in BA 7300, because they have been tested and meet
the requirements.
Information on the type, quantity and viscosity of the oil is given on the rating plate on the gear
unit.
The oil quantity shown on the rating plate is to be understood as an approximate quantity. The
marks on the oil sight glass indicate the prescribed oil quantity to be put in.
In case of gear units fitted with forced lubrication or an oilcooling system, the oil circuit must
also be charged with oil. To do this, briefly start up the gear unit with addon pump (observing
the description in section 8).
• Check the oil level in the gearunit housing.
The oil level must be at the upper mark on the oilsight glass.

• Place the fastening bolts of the cover and tighten them to the specified torque (see item 6.13).
7.1.3 Oillevel monitoring system
This monitoring is designed as a standstill monitoring (gear unit stop) and checks the level of
the oil before the unit is started up. It should be wired in such a way that, when the signal "oil
level too low" is given, the drive motor cannot start and that an alarm is given. During operation,
any active signal should be bridged.
7.1.4 Heating
Never switch the heating on, unless complete immersion of the rod heater in the oil
bath is ensured. Fire hazard!
If heating elements are installed afterwards the maximum heating capacity
(see table 6 in item 5.9) on the outer surface of the heating element must not be
exceeded.
The correct setting of the switch points must be checked!
7.1.5 Reversing device

Before startup the shift lever of the reversing device must be at position "Disengage",
the stop knob engaged and the locking screw tightened.
BA 5020 en 06/2010
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7.2 Preparing the startup
All data must be recorded (see items 7.2.1 to 7.2.3).
7.2.1 Checking procedure

The following visual checks must be conducted and recorded when starting up:
• Oil level.
The oil level must be monitored by means of the existing oillevel monitoring equipment. To do so, the gear
unit must be shut down.
When the oil is cool, the oil level should be at the upper mark on the oilsight glass. When the oil is warm
it may slightly exceed this mark.
It must in no case be allowed to fall below the mark. If necessary, top up to the correct
level.
• Leaktightness of the oilcooling or oilsupply lines.

• Opening condition of the shutoff valves.
• Effectiveness of the shaft seals.
• Freedom of the rotating parts from contact.
The alignment dimensions in accordance with items 6.3.2.1 to 6.3.2.4 and the tensioning pressures and
the initialtensioning forces in accordance with 6.3.2.2 to 6.3.2.4 must also be recorded in this document.
The document must be kept with the instructions.
7.2.1.1 Gear unit with oilsupply system

• Fully open the stop valves in the coolant in and outflow pipes of the cooling system.
• Check that connecting lines are correctly fastened and tight.
For connecting dimensions, refer to the dimensioned drawing of the gear unit. The required
coolingwater quantity and the maximum permissible inlet temperature are given on the data
sheet and/or the list of equipment.
The gear unit must be operated only together with the oilsupply system. For this the
oilsupply system must be switched on at least 2 minutes before starting up the gear
unit.
The permissible pressure and temperature values specified in the data sheet and/or list of
equipment must not be exceeded.
This is to be checked before the startup.
• Start the drive motor.

7.2.2 Temperature measurement
During first startup and after maintenance work, the oilsump temperature must be
measured during correct use (maximum machine performance) after appropriate
running in.
The maximally permissible oilsump temperature is 90 °C (for mineral oil) or 100 °C

(for synthetic oil).
At higher temperatures the gear unit must be shut down immediately and Siemens
customer service consulted.
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7.2.3 Bearing monitoring (vibration measurement)
If the necessary measures have been made for vibration measurement as bearing
monitoring (see item 5.13.2), vibration measurements must be taken in order to obtain
initial values and/or standard values for the diagnosis. These measurements must be
recorded and filed.
7.3 Removal from service

• To take the gear unit out of service, first switch off the drive unit.
Secure the drive unit to prevent it from being started up unintentionally.
Attach a warning notice to the start switch!
• With gear units fitted with water oilcoolers, close the stop valves on the water in and outflow pipes.
If there is danger of freezing, drain the water from the water oilcooler.
• Start the gear unit and allow it to run briefly (5 to 10 minutes) approx. every 3 weeks (during a shutdown
period no longer than 6 months).
• Treat the gear unit with preservative, see items 7.3.1 and 7.3.2 (before a shutdown period exceeding
6 months).
7.3.1 Interior preservation during longer disuse
Depending on the type of lubrication and/or shaft sealing, the following types of interior preservation can
be applied.
7.3.1.1 Interior preservation with gear oil
Gear units with splashlubrication systems and contacting shaft seals can be filled with the correct type of
service oil up to a point just below the air filter.
7.3.1.2 Interior preservation with preservative agent
Before longer shutdown periods gear units with forcedlubrication systems, oil circulation cooling and/or
noncontacting shaft seals should be filled with preservative agent and run without load.
BA 5020 en 06/2010
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7.3.1.3 Interiorpreservation procedure
• Stop the gear unit.
• Drain oil into a suitable container (see section 10, "Maintenance and Repair").
Using a filter (approx. mesh 25 μm), fill the gear unit with fresh preservative oil up to
the MAX mark on the oilsight glass.
For preservative agent see table 2 or 3 in item 4.4.2.

• Place the fastening bolts of the inspection and/or fitting cover and tighten them to the specified torque
(see item 6.13).
• Start the gear unit and allow it to idle briefly.
• Unscrew the oildrain plug.
• Drain preservative agent into a suitable container.
• Dispose of preservative agent in accordance with regulations.

There is a risk of scalding from the hot preservative agent draining from the gear unit.
Wear safety gloves and safety glasses!
• Screw in the oildrain plug.

• Replace the air filter with the screw plug.
Before restarting the gear unit, replace the screw plug with the air filter. Observe the
instructions in item 7.1.1.
The labyrinths must be sealed at the shafts (only in case of Tacolab seals, see
item 4.4.1). Before restarting the gear unit, replace the adhesive tape from the
labyrinth seals. Observe the instructions in item 7.1.1.
7.3.2 Exterior preservation

7.3.2.1 Exteriorpreservation procedure
• Clean the surfaces.
For separation between the sealing lip of the shaftsealing ring and the preservative agent, the
shaft should be brushed with grease in way of the sealing lip.
• Apply preservative agent.
For preservative agent see table 4 in item 4.4.3.
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8. Operation
Observe the instructions in section 3, "Safety instructions", in section 9, "Faults, causes and remedy", and
in section 10, "Maintenance and repair"!
8.1 General
To achieve a satisfactory and troublefree operation of the equipment, be certain to observe the operating
values specified in section 1, "Technical Data", as well as the information given in the operating instructions
of the oilsupply system, if applicable.
During operation the gear unit must be monitored for:
• Operating temperature Unless otherwise agreed, the gear unit is designed for continuous
operation at an operating temperature of:
90 °C (applies to mineral oil)
The maximum permitted temperature is:
100 °C (applies to synthetic oil)
• Oil pressure of the oilsupply system (min. 0.5 bar).
• Changes in gear noise.
• Possible oil leakage at the housing and shaft seals.
8.2 Oil level
To check the oil level, stop operation of the gear unit.
When the oil is hot, the oil level may be slightly above the top mark on the oil sight glass.
It must not be allowed to fall below the lower mark. If necessary, top up to the correct
level.
After starting up the addon oilsupply system, if fitted, for the first time, the gearunit oil level
must be checked.
8.3 Irregularities
The drive unit must be switched off at once,
– if irregularities are found during the operation
or
– if the pressure monitoring device in the oilcooling system triggers alarm (only with
correspondingly equipped gear units).
Determine the cause of the fault, using table 9, "Faults, causes and remedy" (see
item 9.2).
Table 9, "Faults, causes and remedy", contains a list of possible faults, their causes
and suggested remedies.
If the cause cannot be found, a specialist from one of our customerservice centres
should be called in (see section 2).
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9. Faults, causes and remedy
Observe the instructions in section 3, "Safety instructions", and in section 10, "Maintenance and repair"!
9.1 General information on faults and malfunctions
Faults and malfunctions occurring during the guarantee period and requiring repair work on the
gear unit must be carried out only by Siemens customer service.
In case of faults and malfunctions occurring after the guarantee period and whose cause
cannot be precisely identified, we advise our customers to contact our customer service.
Siemens will not be bound by the terms of the guarantee or otherwise be responsible
in cases of improper use of the gear unit, modifications carried out without Siemens’
agreement or use of spare parts not supplied by Siemens.
To remedy faults and malfunctions, the gear unit must always be taken out of service.
9.2 Possible faults

Table 9: Faults, causes and remedy
Faults Causes Remedy
Sudden machine stop. Driven machine blocked. See item 9.3.

Changes in gearunit noise. Damage to gear teeth. Contact Customer Service.
Check all toothed components
and replace any damaged parts.
Excessive bearing play. Contact Customer Service.

Adjust bearing backlash.
Bearing defective. Contact Customer Service.

Replace defective bearings.
Loud noises in the area of the Gearunit fastening has worked Tighten bolts / nuts to specified
gearunit fastening. loose. torque.
Replace damaged bolts / nuts.
Increased temperature at the Oil level in gearunit housing too low Check oil level at room temperature
bearing points. or too high. and, if necessary, top up oil.
Oil too old. Check date of last oil change and,

if necessary, change oil.
See section 10.
Oilsupply system defective. Check the oilsupply system,

replace any defective parts. Consult
operating instructions for oilsupply
system.
Bearing defective. Contact Customer Service.

Check and, if necessary,
replace bearings.
Exterior of gear unit is oiled up. Inadequate sealing of housing Seal joints.
covers and/or joints.
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Faults Causes Remedy
Oil leakage from the gear unit. Inadequate sealing of housing Check and, if necessary,
covers and/or joints. replace sealings. Seal joints.
Radial shaftsealing rings defective. Check radial shaftsealing rings and,

if necessary, replace.
Oil foaming in the gear unit. Preservation agent not completely Oil change.
drained.
Oilsupply system has been Stop oilsupply system.

operated too long at low Allow the oil to degas.
temperatures.
Gear unit too cold in operation. Shut down gear unit and have oil
degassed. Restart without cooling
water.
Water in oil. Test the oil, change oil if necessary.
Oil too old Test the oil, change oil if necessary.

(defoaming agent used up).
Unsuitable oils mixed up. Test the oil, change oil if necessary.
Water in oil. Oil foams in sump. Check state of oil by the testtube
method for water contamination.
Have oil analysed by laboratory.
Oilsupply system. Check the oilsupply system,

replace any defective parts. Consult
system.
Gear unit exposed to cold air from Protect gear unit with suitable heat
machineroom ventilator: water insulation. Close air outlet or alter its
condensing. direction by structural measures.
Climatic conditions. Contact Customer Service.

If necessary, fit wetair filter.
Increased operating Oil level in housing too high. Check oil level and, if necessary,
temperature. adjust.
Oil too old. Check date of last oil change and,

if necessary, change oil.
See section 10.
Oil badly contaminated. Change oil. See section 10.
Oilsupply system Check the oilsupply system, replace

any defective parts. Consult
system.
Fault in oilsupply system. Consult operating instructions for

oilsupply system.
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9.3 Removal of blockages (only if reversing device available)
9.3.1 Switching the reversing device on
Switch the motor of the main drive off.
• Undo safety screw.

• Pull stop knob.
• Move shift lever into position "Engaged" (see item 5.15.1).
The clutch in the bell housing will now connect the reversing device to the main gear unit.
• Engage the locking bolt.

• Tighten locking screw.
The shifting procedure must alwas occur during a standstill.
• Start the motor of the reversing device (see item 5.15).

9.3.2 Switching the reversing device off
• Undo safety screw.
• Pull stop knob.
• Move shift lever into position "Disengaged" (see item 5.15.1).
The clutch in the bell housing is now no longer connected to the reversing device.
• Engage the locking bolt.

• Tighten locking screw.
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10. Maintenance and repair
Observe the instructions in section 3, "Safety instructions", and in section 9, "Faults, causes and remedy"!
10.1 General notes on maintenance
All maintenance and repair work must be done with care and by duly trained and qualified personnel only.
The following applies to all work in item 10.2:

Switch the gear unit and addon components off.

The periods indicated in table 10 depend on the conditions under which the gear unit
is operated. Only average periods can therefore be stated here. These refer to:
a daily operating time of 24 h

a duty factor "ED" of 100 %
an inputdrive speed of 1500 1/min
maximum oil temperature of 90 °C (applies to mineral oil)
100 °C (applies to synthetic oil)
The operator must ensure that the intervals stated in table 10 are adhered to.
This also applies if the maintenance work is included in the operator’s internal
maintenance schedules.
Under different operating conditions the periods indicated below must be adjusted
accordingly.
Table 10: Maintenance and repair work
Maßnahmen Fristen Bemerkungen
Check the oil temperature Daily
Check for unusual gearunit noise Daily
Check the oil level Monthly
Check the gear unit for leaks Monthly
Test the water content of the oil After approx. 400 operating hours, see item 10.2.1
at least once per year
Perform the first oil change Approx. 400 operating hours see item 10.2.2
after startup
Perform subsequent oil changes Every 24 months or see item 10.2.2

10000 operating hours
Clean air filter Every 3 months see item 10.2.3
Clean the gear unit Depending on requirements, see item 10.2.4

at least every 2 years
Refill the Taconite seals with grease Every 3000 operating hours see item 10.2.5
or at least every 6 months
Refill Tacolab seals with grease Every 3000 operating hours see item 10.2.6
or at least every 6 months
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Maßnahmen Fristen Bemerkungen
Check the hose lines Yearly see item 10.2.7
Change the hose lines 6 years from the manufacturing see item 10.2.7
date impressed
Check tightness of screw After first oil change, see item 10.2.9
connections then every 2 years
Inspection of the gear unit Approx. every 2 years see item 10.4.
10.1.1 General oilservice lives

According to the oil manufacturers, the following are the expected periods during which the oils can be
used without undergoing any significant change in quality. They are calculated on the basis of an average
oil temperature of 80 °C:
─ for mineral oils, biologically degradable oils and physiologically safe (synthetic esters) oils 2 years
or 10 000 operating hours (does not apply to natural esters, such as rape seed oils).
─ for poly-α-olefins and polyglycols, 4 years or 20 000 operating hours.
The actual service lives may differ. The general rule is that an increase in temperature of 10 K
will halve the service life and a temperature decrease of 10 K will approximately double the
service life.
10.2 Description of maintenance and repair works

10.2.1 Test water content of oil
More information about examining the oil for water content or conducting oil analyses is obtainable from
your lubricant manufacturer or our customer service.
• For reference purposes, a fresh sample of the operating lubricating oil used must be sent with the used
oil sample to the analysing institute for analysis.
• The oil sample must be taken downstream of the filter of the oilsupply system while the gear unit is
running. A suitable connection point is normally located upstream of the gear unit input (e.g. oildrain
cock in the pressure line).
• A special sample container should be filled with the specified quantity of oil.
If there is no such sample container available, at least one litre of oil must be put in a clean,
transportworthy, sealable vessel.
10.2.2 Change oil
As an alternative to the oilchange intervals indicated in table 10 (see item 10.1) it is possible to have the
oil sample tested at regular intervals by the Technical Service of the relevant oil company and to have it
released for further use.
If reusability has been confirmed, no oil change will be necessary.
Please observe the separately attached operating instructions BA 7300.
• The instructions in item 7.1 must be observed!

• Drain the oil while the gear unit is still warm, i.e. immediately after shutting down the machinery.
When changing the oil, always refill the gear unit with the same type of oil. Never mix
different types of oil and/or oils made by different manufacturers. Polyglycolbased
synthetic oils in particular must not be mixed with PAObased synthetic oils or mineral
oils. If changing to a different grade or make of oil, the gear unit must, if necessary, be
flushed out with the new oil grade. Flushing is not necessary, if the new service oil is
fully compatible with the old service oil in all respects. Compatibility must be
confirmed by the oil supplier. If there is a change to another oil grade or make, Siemens
recommends flushing out the gear unit with the new grade of service oil.
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When changing the oil, the housing and the oilsupply system, if available, must be flushed with
oil to remove sludge, metal particles and oil residue. Use the same type of oil as is used for
normal operation. Highviscosity oils must be heated beforehand using suitable means.
Ensure that all residues have been removed before filling with fresh oil.
• Place a suitable container under the oildraining point of the gearunit housing.
• Unscrew the air filter including reducing screw at the housing top.
• Unscrew the screw plug or the open oildrain cock and drain the oil into the collecting container.
• Drain the oil from the oilsupply system (see operating instructions to the oilsupply system).
There is a danger of scalding from the hot oil emerging from the housing.
Wear safety gloves and safety glasses!
Check the condition of the sealing ring (the sealing ring is vulcanised onto the oildrain plug).
If necessary, use a new oildrain plug.
• Screw in the screw plug again and shut the oildrain cock.
• Clean the oil filter in the oilcooling system (see operating instructions of the oilsupply system).
• Clean the air filter (see item 10.2.3).
• Screw in the air filter including reducing screw.
• Fill fresh oil into the gear unit (see item 7.1.2).
10.2.3 Clean the air filter
If a layer of dust has built up, the air filter must be cleaned, whether or not the minimum period
of 3 months has expired.
• Unscrew the air filter including the reducing screw.

• Clean the air filter using benzine or a similar cleanser.
• Dry the air filter and/or blow with compressed air.
Be especially careful when blowing with compressed air.
Wear protective glasses!
Foreign bodies must be prevented from entering the gear unit.
10.2.4 Clean the gear unit

• Remove any corrosion.
The gear unit must not be cleaned with highpressure cleaning equipment.
10.2.5 Refill Taconite seals with grease

• Inject approx. 30 g lithiumbased rollingbearing grease into each of the lubrication points of the
Taconite seal. The lubricating points have been provided with grease nipples.
For the exact arrangement of the grease nipples, refer to the drawings in the gearunit
documentation.
Remove and dispose of any old grease escaping.
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10.2.6 Refill Tacolab seals with grease
• Inject approx. 30 g lithiumbased bearing grease into each of the lubrication points of the Tacolab seal.
The lubricating points have been provided with grease nipples.
For the exact arrangement of the grease nipples, refer to the drawings in the gearunit
documentation.
Remove and dispose of any old grease escaping.
10.2.7 Check hose lines

Even when adequately stored and subjected to permissible loads, hoses and hose lines are subject to
a natural ageing process. This limits their period of use.
The period of use of the hose lines must not exceed 6 years from the manufacturing
date stamped on them.
The period of use can be determined using available test and empirical values, taking into account the
conditions of use.
The operator of the system must ensure that hose lines are replaced at suitable intervals of
time, even if no defects which may affect their safe operation are identifiable on them.
Hose lines must be inspected for safe working condition by an expert before the plant is first
put into operation and thereafter at least once a year.
If during inspections faults are found, these must be rectified immediately or suitable
countermeasures taken.
10.2.8 Top up oil

• Always top up with the same type of oil as already used in the unit (see also item 10.2.2).
10.2.9 Check tightness of screw connections
• Close the stop valves in the coolant in and outflow pipes (for gear units with water oilcooling system).
• Check tightness of all screw connections (see item 6.13).
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10.3 Final work
For operating and servicing the components, the pertinent instruction manuals and the
specifications in sections 5 and 7 must be observed.
Observe also item 6.12.
10.4 General inspection of the gear unit

The general inspection of the gear unit should be carried out by the Siemens Customer Service, as our
engineers have the experience and training necessary to identify any components requiring replacement.
Assembly or disassembly of the DUORED helicalgear unit must only be carried out
by trained and qualified Siemens personnel in accordance with the internal Siemens
assembly instructions and using the equipment required for such operations.
10.5 Oilsupply system

Be sure to observe the operating instructions of the oilsupply system for operation and
maintenance.
10.6 Lubricants
The quality of the oil used must meet the requirements of the separately supplied BA 7300 operating
instructions, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one of
the oils listed in BA 7300, because they have been tested and meet the requirements.
To avoid misunderstandings, we should like to point out that this recommendation is in no way
intended as a guarantee of the quality of the lubricant supplied. Each lubricant manufacturer
is responsible for the quality of his own product.
Information on the type, quantity and viscosity of the oil is given on the rating plate on the gear unit and/or
in the supplied documentation.
The quantity of oil indicated on the rating plate is an approximation only. The marks on the oil dipstick or
oilsight glass are decisive for the amount of oil to be filled in.
The manual containing the current lubricants recommended by Siemens can also be consulted on the
internet (see back cover).
The oils listed there are subjected to continuous tests. Under certain circumstances the oils recommended
there may therefore later be removed from the range or replaced with further developed oils.
We recommend regularly checking whether the selected lubricating oil is still recommended by Siemens.
If it is not, the brand of oil should be changed.
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11. Spare parts, customerservice
11.1 Stocking spare parts

By stocking the most important spare and wearing parts on site you can ensure that the gear unit is ready
for use at any time.
To order spare parts, refer to the spareparts list.
For further information refer to the spareparts drawing stated in the spare parts list.
We guarantee only the original spare parts supplied by us. Nonoriginal spare parts
have not been tested or approved by us. They may alter technical characteristics of
the gear unit, thereby posing an active or passive risk to safety. Siemens will assume
no liability or guarantee for damage caused by spare parts not supplied by Siemens.
The same applies to any accessories not supplied by Siemens.
Please note that certain components often have special production and supply specifications and that we
supply you with spare parts which comply fully with the current state of technical development as well as
current legislation.
When ordering spare parts, always state the following:
Order number, item Type, size Part number Quantity
11.2 Spare parts and customerservice addresses
When ordering spare parts or requesting a service specialist, please contact Siemens first (see section 2).
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Further Information:
"FLENDER gear units" on the Internet
www.siemens.com/gearunits
"FLENDER couplings" on the Internet

www.siemens.com/couplings
Service & Support:

http://support.automation.siemens.com/WW/view/en/10803928/133300
Lubricants:
http://support.automation.siemens.com/WW/view/en/42961591/133000
Siemens AG Subject to modifications

Industry Sector
Mechanical Drives © Siemens AG 2010
Alfred-Flender-Straße 77
46395 Bocholt
GERMANY
www.siemens.com/drivetechnologies
Page 59
力保密作出
。留转为于
所交企信
有。业任
权机，
Tolerancing ISO 8015 / ISO 2768-mH

General tol. for machining <=30 ±0.3
©
Page 60
SPARE PART LIST
GEARBOX DESCRIPTION : SVVL 700
SALES ORDER NO. : 3005260862
SPARE PART DRG. NO. : A5E43680749A
PART NO. MATERIAL NO. DESCRIPTION QTY.
0040 A5X00464054 OIL LEVEL INDICATOR 1
0054 102554189 AIR FILTER 1
0090 A5X00361827 RTD 1
0100 A5E42635891 PINION SHAFT LH 1
0132 102585741 SHAFT SEAL SHAFT SEAL 100X130X12 1
0142 102585741 SHAFT SEAL SHAFT SEAL 100X130X12 1
0150 A5E34825781 ROLLG BRG 1
0151 A5E36114938 ROLLG BRG 1
0152 A5X00775924 ROLLG BRG 1
0168 106033066 RTD 1
0169 106033066 RTD 1
0170 106031338 RTD 1
0200 A5E42730526 SHAFT 1
0202 102565434 CYLINDRICAL GEAR 1
0232 102585807 SHAFT SEAL 460X500X20 1
0250 102583360 ROLLG BRG 2
0251 102583630 BEARING K81230 M 2
0270 106031329 RTD 2
0299 A5E42705632 PINION COMPLETE (UP) 1
0350 102583314 ROLLG BRG 2
0399 A5E42705680 PINION COMPLETE (LOW) 1
0450 102583314 ROLLG BRG 2
0451 102583642 ROLLG BRG 2
0480 102900231 FLANGE SHAFT 1
0499 A5E42706191 PINION COMPLETE 1
0550 102583313 ROLLG BRG 2
0600 A5E42696164 PINION SHAFT 1
0602 A5E42687249 CYLINDRICAL GEAR 1
0650 A5X00379192 ROLLG BRG 2
Confidential Page 61
Lubrication Unit
Page 62
Page 63
©
©
Page 64
LIST OF EQUIPMENT Page / of
PROJECT: DAINSA 1/4
Please quote in correspondance Material No. Rev.
3005260862/10 A5E42065939 AA
Name Department Date Date of revision Doc No. Type / Size
Sekaran SEO 30.05.2017 . A5E42065939A 22700 Kcal/hr
Quantity Description Part-No. Manufacturer Mat. No.
P&ID Drawing No. : A5E42066043A

Lub Unit GA Drawing No. : A5E42066165A
Altitude above Mean Sea Level : <1100m
Min. Ambient temperature : 15° C
Max. Ambient temperature : 40° C
Supply voltage : 460 V ±10%, 3-ph AC
Frequency 3-ph AC : 60 Hz ± 5%
Control voltage : 110 v ± 10%, 1-ph AC
Frequency 1-ph AC : 60 Hz ± 5%
Signal voltage : 24 V ± 10% DC
Oil viscosity: Mineral oil : ISO VG 460
Protection Class Motor : IP 55 ISO F acc. To B
Protection Class Instruments : IP 65
Protection Class Terminal Boxes : IP 66
Paint shade : RAL 5015 (Sky blue)
3 Ball valve 7 DELTA

Connection: 2“ Screwed
Nominal pressure: 150 #
Housing material: CS
2 Pump with inbuilt relief valve 10 ROTODEL

Model No: HGBX-150S
Type: Gear
Flow rate: 110 LPM
Speed: 1440 rpm
Output pressure: 5 bar (Max.)
Body: C. I.
2 Flexible Coupling 11 KTR / LOVE JOY

Model No. : 28.1A.1A (only for reference)
Type : ROTEX
Size : 28
Suitable for MPA
2 Three-phase Electric Motor 12 SIEMENS

Type: 1SE0 **
TEFC, Frame size; **
Power Rating: 7.5 HP (5.5 kW)
Speed: 1440 rpm
Voltage: 460 V, 3-phase AC
Frequency: 60 Hz
Insulation Class F
Type of protection: IP 55
1 Duplex Basket Filter 20 OEM

Type: Casted / Fabricated
Connection 40 NB
Rate of Oil Flow: 110 lpm
Filter mesh size: 60 micron
Filter element material: SS 304
SIEMENS LIMITED
Page 65
PROJECT: DAINSA 2/4
3005260862/10 A5E42065939 AA
1 Differential pressure Switch 21 DANFOSS

Object: 017D002566
Description : RT262A, M/9
Enclosure rating: IP66
Pressure connection: G3/8 M
Contact function: SPDT
Contact rating: AC1=10A,400V – AC15=3A,400V – AC3=4A,400V – DC13=12W,220V – LR=28A,400V
Differential range: 0.1 to 1.5 bar
Set Point: 0.7 bar (rising)
Logic: Alarm for filter clogging
2 Needle valve 22 OEM
1 Oil Cooler 30 ALFA LAVAL

Type: Plate type ( M3-FG)
Cooling efficiency: 22700 Kcal/hr (26.4 KW)
Rate of oil flow approx.: 110 lpm;
Oil temperature cooler inlet / outlet: 75 / 67° C
Cooling water quantity required: 31.3 lpm
Water temperature cooler inlet / outlet: 32 / 44° C
2 Non-return Valve 35 DELTA

Type: Non slam
Connection: 1 1/2“ Flanged
Nominal pressure : 150#
Housing material : CS
1 Pressure Gauge 45 GIC

Model No. : AL-F-2-3BM-(0-7 KG/CM²) (only reference)
Type: for reading only
Range: 0-7 bar
Dial size: 100 mm
Case MOC: SS 304
Connection: 3/8” BSP (M)
1 Pressure Switch 50 DANFOSS

Object: 017-529166
Description: RT110, M/15
Pressure connection: G3/8 M
Contact function: SPDT
Contact rating: AC1=10A,400V – AC15=3A,400V – AC3=4A,400V – DC13=12W,220V – LR=28A,400V
Regulation range: 0.2 to 3.00 bar
Set point: 0.7 Bar (falling)
Logic: Alarm for low pressure, auto changeover of pump
1 Temperature Gauge 60 GIC

Model No. : CB-F-2-4BM-ZI-2J-150-0/120°C (only reference)
Type: for reading only
Range: 0-120° C
Dial size: 100 mm
Case MOC: SS 304
Connection: 1/2” BSP (M)
SIEMENS LIMITED
Page 66
PROJECT: DAINSA 3/4
3005260862/10 A5E42065939 AA
1 Flow Switch 80 MUKUND

Model No: SF100+2000S (only reference)
Switching contact form : 1 NO + 1 NC
Flow rate: 110 LPM
Set point: 70 LPM (Falling)
Logic: Alarm for Low Flow
Switching contact rating: 5A, 250/125 V AC
Protection: IP 67
1 Stop (Globe) Valve 87 DELTA

Connection: 3/4“ Screwed
Nominal pressure : 150#
Housing material: CS
1 Temperature Switch 265 DANFOSS

Object: 060L313466
Description: KPS81 Thermostat M/10
Sensor type : Remote sensor with armoured tube
Connection for pocket or hose: M18 x 1.5
Contact function: SPDT gold
Contact rating: AC1=10A,400V– AC15=4A,440V–AC3=6A,440V–DC13=12W,220V–gold=30mA,30V
Temperature range: 60-150° C
Set point: 90°C for trip
SIEMENS LIMITED
Page 67
PROJECT: DAINSA 4/4
3005260862/10 A5E42065939 AA
INTERLOCKING INSTRUCTIONS
When enabling and determining starting condition for pumps, it must be ensured that temperature
values are based on VG 460 mineral oil. If other oils are used, the viscosity of the oil for that temperature
value must not be higher.
GEAR UNIT ENABLE is given when the following conditions are fulfilled:
- Filter differential pressure < 0.7 bar
- Oil pressure > 0.7 bar
- Oil flow quantity > 70 l/min
WARNING is given when one of the following conditions is fulfilled:

- Differential pressure of filter > 0.7 bar after a time span of 30 seconds
- Oil pressure < 0.7 bar ( SWITCH OVER TO STANDBY PUMP)
GEAR UNIT STOP is given when one of the following conditions is fulfilled:
- Oil temperature > 90°C
Run-up time of oil-supply system at least 2 minutes
If GEAR UNIT TRIPS when 90°C is reached the oil cooler need to be checked before starting the
gear unit again.
If the temperature of the oil is above 90°C at GEAR UNIT STOP, the oil pump should remain switched on
until a temperature of < 80°C is reached.
REVISION DETAILS
Revision Change Description Part No Revised By Date
SIEMENS LIMITED
Page 68
Gear-unit lubrication
for
helical gear units, bevelgear units,
bevelhelical gearunits, planetarygear units
and geared motors
(with the exception of wormgeared motors)

BA 7300 EN 11/2010
FLENDER supplies
Page 69
Lubricating oils 12
1
Gear-unit lubrication 12
2
Lubricating greases
Check list for

oil filling and oil change 12
3
for
helical gear units, bevelgear units, Documentation sheet
bevelhelical gearunits, for oil change 12
4
planetarygear units and geared motors
12
Assembly and operating instructions 12

12
12
12
12
12
12
BA 7300 EN 11/2010
2 / 17 Page 70
or "manual".
Legal notes
NOTE!
Qualified personnel
BA 7300 EN 11/2010
3 / 17 Page 71
observed.
Trademarks
Symbols
Connection for
Oil level red
Do not unscrew
BA 7300 EN 11/2010
4 / 17 Page 72
Gear-unit lubrication
for
helical gear units, bevelgear units,
bevelhelical gearunits, planetarygear units
and geared motors

BA 7300 EN 11/2010
FLENDER supplies
Page 73
Lubricating oils 12
1
Gear-unit lubrication 12
2
Lubricating greases
Check list for

oil filling and oil change 12
3
for
helical gear units, bevelgear units, Documentation sheet
bevelhelical gearunits, for oil change 12
4
planetarygear units and geared motors
12
Assembly and operating instructions 12

12
12
12
12
12
12
BA 7300 EN 11/2010
2 / 17 Page 74
or "manual".
Legal notes
NOTE!
Qualified personnel
BA 7300 EN 11/2010
3 / 17 Page 75
observed.
Trademarks
Symbols
Connection for
Oil level red
Do not unscrew
BA 7300 EN 11/2010
4 / 17 Page 76
Contents
1. Lubricating oils for helical gear units, bevelgear units,

bevelhelical gearunits, planetarygear units and geared motors
(with the exception of wormgeared motors) . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Oil groups and base oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Quality, code numbers, approval lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.1 Required quality of the gear oils to be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.2 Code numbers, approval lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Oil temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 General service lives of oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Information about initial filling and oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Safety at work, environmental protection and general information . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.7 Procedure for emptying the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7.1 Draining off the used oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7.2 Checks and work to be done before refilling the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8 Putting in the fresh gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.9 Flushing procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.10 Procedure when changing the type of oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2. Lubricating greases for gear units and rolling bearings . . . . . . . . . . . . . . 14
3. Check list for oil filling and oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4. Documentation sheet for oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BA 7300 EN 11/2010
5 / 17 Page 77
1. Lubricating oils for helical gear units, bevelgear units, bevelhelical
gearunits, planetarygear units and geared motors (with the exception of
wormgeared motors)
These assembly and operating instructions do not apply to gear units made by
WINERGY AG and Flender Graffenstaden S.A.S. These plants provide different
instructions.
For "FLENDER gear units" not referred to in these assembly and operating instructions the
following manuals will apply:
Ship’s gearboxes: BA 7301

Wormgear unit: BA 7303
1.1 Oil groups and base oils

Siemens Mechanical Drives (MD), Bocholt, distinguishes between the following oil groups in regard to
gear oils for FLENDER gears:
• Standard oils
• Biologically degradable oils (also called "BIO" for short)
• Physiologically safe oils approved in accordance with NSFH1 (also called "PHY" for short)
The tested and recommended gear oils can be manufactured on the basis of the following four base oils:
• Mineral oils
• Poly-α-olefins (also called "PAO" for short)
• Polyglykole (also called "PG" or "PAG" for short)
• synthetic esters
Theoretically all four base oil types may occur in each oil group.
BA 7300 EN 11/2010
6 / 17 Page 78
1.2 Quality, code numbers, approval lists
1.2.1 Required quality of the gear oils to be used
For "FLENDER gear units", Siemens approves only CLP quality oils which contain constituents
to DIN 515173 for improvement of corrosion prevention and resistance to ageing and which reduce wear
in mixedfriction areas. The oils must have passed the following tests (see also Specification of gear oil
approvals for FLENDER gear units):
• Scuffing resistance in the FZGtest to DIN ISO 146351 Fail stage > 12
under A/8.3/90 test conditions
• FE8 rollingbearing test to DIN 518193 under Rollingelement wear < 30 mg
D7.5/8080 test conditions Cage wear < 100 mg
• Resistance to grey staining to FVA 54 IIV GS fail stage ≥ 10
Resistance to grey staining GFT = high
• Flender foam test < 15 % increase in volume 1 minute
after switching off
• Static and dynamic “FLENDERFreudenberg test” Approval by Messrs. Freudenberg
for shaft sealing rings
• Compatibility with liquid seals Approval by Messrs. Loctite
• "FLENDERMäderFarbtest" (colour test) Approval by Messrs. Mäder
Oil group, base oil and viscosity class as stated in the specifications on the rating
plates and information in the gear unit documentation must be adhered to!
Failure to do so will result in invalidation of the guarantee.
The unapproved use of oils which do not comply with the above quality requirements
will invalidate the Siemens product guarantee obligation. In addition adherence to the
instructions given in these operating instructions is conditional for any claims under
warranty.
Deviations are permitted only after consultation with Siemens!
If the operating conditions have been subsequently modified and differ from those
stated in the customer’s order, the gear oil to be used must be approved by Siemens
in writing.
BA 7300 EN 11/2010
7 / 17 Page 79
1.2.2 Code numbers, approval lists
To help its customers Siemens MD, Bocholt, has grouped oils in approval lists. The abovementioned test
results have been verified to Siemens for these oils by the oil manufacturers. Also worldwide adherence
to the characteristics, features and minimum requirements required by Siemens has been guaranteed by
the oil manufacturers.
Assignment of the approved oils to the oil groups, the base oils and the viscosities is indicated
by code numbers in the approval lists.
Code number A13 indicates e.g. all standard mineral oils with the viscosity ISO VG 460.
The approval lists with the current gear oil recommendations for FLENDER gear units are
available as "FAQ" under the following link on the Internet:
http://support.automation.siemens.com/WW/view/en/44231658
We recommend regularly checking whether the selected lubricant is still approved by

Siemens.
The approval of these gear oils for use in FLENDER gear units and their consequent inclusion in the
relevant lists does not mean that Siemens is liable for the suitability and quality of the oils. Nor is Siemens
liable for any damage caused to FLENDER gear units by the use of these gear oils.
Each gearoil manufacturer is always responsible for the suitability and quality of his own product.
1.3 Oil temperatures
Synthetic gear oils have a wider temperature range and a higher viscosity index (i.e. a flatter
viscositytemperature gradient) than mineral oils.
The operating temperature range of the base oils most frequently used can be approximately specified as
follows:
─ Mineral oils approx. 10 °C to + 90 °C (short term + 100 °C)

─ Polyglycols and poly-α-olefins approx. 20 °C to + 100 °C (short term + 110 °C)
─ Synthetic esters approx. 20 °C to + 90 °C
The upper and lower operating temperatures of certain gear oils may deviate widely from the
values indicated. For operating conditions outside the abovementioned temperature ranges
the flash point and pour point provide information which must normally not be understood to
represent operating limit values. For data on and characteristics of the gear oils please see the
oil manufacturers’ technical data sheets and safety data sheets.
The operating temperatures of the gear unit and the type of base oil must not be
changed without consulting Siemens!
1.4 General service lives of oils

The service lives set out below are guaranteed by the oil manufacturers for the gear oils approved by
Siemens (see also item 1.2) without substantial changes in oil qualities.
These specifications apply to an average oil temperature of 80 °C in the oil sump of the gear unit.
─ Mineral oils and synthetic esters 2 years or 10 000 operating hours

─ Poly-α-olefins and polyglycols 4 years or 20 000 operating hours
Actual service lives may deviate from these. Here the rule applies that a temperature rise
of 10 K will roughly halve and a temperature reduction of 10 K will roughly double the service
life.
BA 7300 EN 11/2010
8 / 17 Page 80
1.5 Information about initial filling and oil change
The purity level of the gear oil affects the operational reliability and service life of the oil and the gear unit.
Accordingly, care should be taken to use only clean oil in the gear unit. For initial filling and oil changes the
supplementary specifications, if any, in the gear unit instructions must also be observed.
Careful initial filling and careful oil changing contribute considerably to an increase in the operational
reliability and service life of both the gear unit and the oil.
When putting in and changing oil no impurities such as foreign bodies, water or other
liquids must be allowed to get into the interior of the gear unit.
In the case of large quantities of oil it is recommended to carry out an oil analysis to determine
whether the oil needs to be cleaned or changed.
For recording purposes it is recommended to use table 2 (see section 4).
1.6 Safety at work, environmental protection and general information

All work carried out on the gear unit must be carried out carefully and by qualified personnel only
(see also "Qualified Personnel" on page 3 of these instructions).
The following regulations and documents must be adhered to:
─ Regulations for safety at work and environmental protection.
─ Regulations for the disposal of used oil.
Gear oils are recyclable materials. Local legal requirements must be observed when disposing
of them.
─ Product data sheets for the oils used, including flushing oil, if necessary
─ Safety data sheets for the oils and aids used
─ Operating and maintenance instructions for the gear units scheduled for initial filling or oil change,
including the oil supply system
─ Documentation sheet for oil change (see table 2)
The following preparations must be made on the gear unit:
─ Suitable body protection must be used (skin care media, gloves, work shoes, safety glasses, ear
protectors, etc.).
─ Sufficient space and cleanliness in the work place must be ensured.
─ Provision of following aids and parts:
─ suitable oilcollecting and/or extraction equipment of a sufficient size
─ suitable cleaned equipment and containers for oil sampling
─ suitable equipment for marking the oil sample
─ sufficient quantity of clean flushing oil (if necessary)
─ correct type and sufficient quantity of fresh oil for refilling the gear unit
─ cleaned filling system and further aids, including filling filters
─ fresh seals (if necessary)
─ oil binding and cleaning media
─ lintfree, clean cleaning cloths in sufficient quantity
For initial filling the procedure set out in item 1.8 must be adhered to.
BA 7300 EN 11/2010
9 / 17 Page 81
1.7 Procedure for emptying the gear unit
It is recommended to use the check list in table 1 as an aid.
Before changing the oil a sample of the oil, still hot from operation, should always be properly drawn from
the gear unit, documented and kept for later examinations.
1.7.1 Draining off the used oil filling
─ Note information given in the operating instructions for draining off the used oil. This also applies
particularly to central lubricating systems and other oil supply equipment. If no relevant information is
given, the lowest possible point must be used to drain off or suck out the oil.
─ Shut down gear unit and ensure that it cannot be started up.
─ Check and record oil level.
An oil level above the max mark may indicate that a foreign liquid (e.g. water) has got in.
An oil level below the min mark may indicate that there is a leak. Both conditions must be rated
as a fault and may result in damage to the gear unit. The cause must be found and, if necessary,
rectified before refilling!
After shutting off the gear unit the oil should be changed as soon as possible to prevent any
solid matter from settling.
Should this not be possible, the gear unit must be run again for a short while before draining
off the oil.
The oil should as far as possible be drained off while it is still hot (approx. 50 °C).
Risk of scalding from escaping hot oil!
─ Visual check for possible leakage. If there is leakage, the cause must be found and rectified before
refilling.
─ Before draining off or sucking out the oil open all vent holes provided.
─ Position the oil collector under the oil drain.
─ Drain off or suck out oil and, if necessary, also empty all oil pockets.
Open drain carefully.
─ The oil draining off must be collected in accordance with regulations. If necessary, ancillary units
(such as oil supply systems, filters) and pipework must likewise be emptied.
─ On gear units with an oil circulation system and on oil supply systems the oilconducting system must
be emptied in accordance with the manufacturer’s instructions in the operating and maintenance
instructions.
─ Any spilled oil must be immediately bound with suitable material and disposed of in accordance with
regulations!
Any spilled oil must be immediately bound with oil binding material and disposed of
in accordance with regulations!
BA 7300 EN 11/2010
10 / 17 Page 82
1.7.2 Checks and work to be done before refilling the gear unit
─ The quantity of oil drained off must be compared with the manufacturer’s rated quantity. If despite
a correct oil level the quantity is considerably less than the rated quantity, it must be assumed that there
are considerable quantities of used oil remaining in the gear unit and/or the ancillary units.
In this case the flushing procedure set out in item 1.9 must be followed.
─ The oil drained off must be checked visually (appearance, colour, impurities, etc).
─ If there is serious contamination (e.g. by water, metal particles, sludge), a specialist (preferably
a Siemens specialist) must be called in to trace the cause.
The lubricating oil system must then be thoroughly flushed out before refilling (see item 1.9).
─ Oil drain plugs with a magnet or magnetic extractors provided must be inspected for and freed of
abraded metal. If a large amount of abraded metal is suspected, a specialist (preferably a Siemens
specialist) must be called in to trace the cause.
─ On gears with inspection holes the interior of the gear unit must be checked for deposits and the teeth
and bearings checked for damage. Any damage must be repaired. If there are heavy deposits or other
impurities, the flushing procedure set out in item 1.9 must be followed. If it is evident that the impurities
cannot be removed by flushing alone, they must be removed mechanically. Residues may be removed
from storage containers by using a rubber scraper.
Before opening inspection covers on gear units the area around the inspection hole must be
thoroughly cleaned to prevent dirt from getting into the interior of the gear unit from outside
when the cover is opened.
─ Oil filters and seals provided must be cleaned or changed in accordance with regulations.
─ The used oil must be disposed of in accordance with regulations.
Certain synthetic oils or impurities may have to be disposed of by different means from that for
normal used oils. The oil data sheets must be observed.
BA 7300 EN 11/2010
11 / 17 Page 83
1.8 Putting in the fresh gear oil
For initial filling it is recommended to use table 1, "Oilchange check list", from point 27 on as
an aid.
For oil changing the gear unit must be filled only with fresh oil of the type and make
previously used. If necessary, the specifications for the required purity class in the
operating instructions must be observed. The make of oil or even the type of base oil
must not be changed without very good reasons. If the oils previously used and those
subsequently used are incompatible, a flushing procedure must be followed
(see item 1.9).
It is recommended to keep a sample of the fresh oil before filling as a reference sample for later
comparison.
The following steps must be carried out:

─ Clean the seats of the vent covers, drain plugs, etc).
─ If necessary, fit previously new seals on previously opened vent covers, drain plugs, etc., and close.
─ If necessary, a flushing procedure must be followed at this point. Unless otherwise prescribed by the
gear unit and/or oil manufacturer, the procedure as set out in item 1.9 is recommended.
─ Check fresh oil visually for the following parameters:
─ Homogeneity
─ Freedom from solid impurities and water (clouding)
─ Colour and appearance in compliance with the oil manufacturer’s productspecific data
─ Put in fresh oil up to the prescribed fill level.
The oil quantity specified on the rating plates is only a guide value. Decisive for the
quantity of oil to be put in are the marks on the oil dipstick or the other oil level
indication systems.
─ Fresh oil may be contaminated. The oil should therefore be put in through a filter as set out in the
operating and maintenance instructions. If no specifications are available for this, filling filters with a
filter mesh of 10 μm have proved highly effective. It is recommended to preheat the oil to
between 35 and 40 °C. It sometimes also suffices to store the oil to be used to fill the gear unit with for
approx. 2 to 3 days in a room at a temperature of approx. 25 °C before putting it in.
─ If necessary, also fill ancillary units (oil systems, filters, etc.) and pipework.
─ After a short operating time (approx. 10 minutes) and a rest time of at least 15 minutes the oil level must
be rechecked and, if necessary, more oil put in or oil drained off.
It is recommended to take an oil sample approx. 5 operating hours after changing the oil and
to record and keep it for later checking.
─ Fill out and keep the documentation sheet for the oil change (see table 2).
─ After a week at most check the oil filter (if provided) for deposits and, if necessary, clean or replace it.
Impurities still remaining in the system may have dissolved and may be blocking the filters.
BA 7300 EN 11/2010
12 / 17 Page 84
1.9 Flushing procedure
When changing the oil make, particularly the base oil type, if the gear oil put in is badly
contaminated or major repairs have been carried out on the gear unit, a flushing
procedure is necessary before finally filling the system with the operating oil.
If necessary, specifications for flushing included in the gear unit operating instructions must be adhered
to. The following procedure is given only as an example and must be adjusted to suit local conditions.
The described procedure must be scheduled in addition to the activities specified for oil
changing and must be integrated at the appropriate point in the procedure plan.
─ Ensure that gear unit cannot be started up.

─ To prevent incompatibilities the same type of lubricating oil as that to be used later should be used for
flushing. To achieve a better flushing and dissolving effect a lower viscosity level of the same type of
oil may have to be selected. Here the lubrication requirements of all component assemblies, including
the pumps, must be taken into consideration.
The use of special cleaning or flushing oils is possible and is sometimes unavoidable.
If special cleaning or flushing oils are used, prior agreement with the oil supplier and
Siemens is necessary.
─ As with oil changing for the fresh oil as set out in item 1.8, the flushing oil must be visually checked
before use.
─ The system must be filled with the oil designated for flushing until a short run without load or in the
partload range is possible without disruptions
Heated flushing oil improves the flushing action and shortens flushing time. Because of the risk
of scalding 50 °C must not be exceeded.
─ When filling with flushing oil any ancillary units provided must be taken into consideration. If necessary,
these should be filled separately and emptied again after the flushing run.
─ The gear unit must be operated for a short time with the flushing oil filling to ensure that it is mixed
intensively with the residual oil remaining in the system and to as far as possible dissolve impurities.
If no flushing time is specified in the operating and maintenance instructions, at least 10 to 60 minutes
are recommended. The greater the operating oil quantity and the worse the contamination, the longer
the time taken for flushing should be.
It is recommended to clean the flushing oil in the bypass flow during the flushing operation.
─ The flushing oil must then be drained off. The procedure is identical to that followed for draining off the
used oil (see item 1.7.1).
─ The flushing oil must be visually checked. If there are still unacceptable impurities in the oil and/or the
gear unit, this flushing procedure must be repeated until the desired result is achieved.
Depending on its condition, the flushing oil may be cleaned and reused as flushing oil or must be
disposed of.
The flushing oil must not be used as operating oil.
BA 7300 EN 11/2010
13 / 17 Page 85
1.10 Procedure when changing the type of oil
The type of oil should be changed in exceptional cases only for important reasons. When
changing to another base oil type or to an oil with very different additive technology,
incompatibilities may result.
Ultimately only oil manufacturers can judge the compatibility of different gear oils. It is therefore
urgently advisable to involve them in the decision process.
When changing to a lubricating oil with another base oil type or with different additive
technology, the entire system must be thoroughly cleaned and flushed after draining
off the used oil (see item 1.9). In this case the flushing oil may be used at most a second
time to flush out the same gear unit. The flushing oil must then be disposed of.
When changing to a new type of oil of similar composition a flushing procedure as set out in
item 1.9 is likewise to be recommended.
The following points must be additionally observed when changing the type of base oil:
• The compatibility of the new oil with other gear unit components, e.g. sealing materials or varnishes and
paints, must be checked. To be recommended are the oils approved by Siemens (see item 1.2).
• Cavitation problems may arise with oils of a higher density. Larger suction line crosssections may be
required.
2. Lubricating greases for gear units and rolling bearings
For special gear-unit applications, grease lubrication of the bearings may be necessary.
Greases may be used only if their use is specified in the operating instructions for the
gear unit. The relubrication periods must be adhered to.
As well as lubrication, rolling bearing greases are used for the special sealing of bearing points, e.g. with
vertical gearunit connection shafts or against environmental action such as dust or water spray.
In closed gear units with internal oil lubrication the gear oil must not be allowed to mix with
bearing grease.
The approval lists with the current grease recommendations for FLENDER gear units are
available as "FAQ" under the following link on the Internet:
http://support.automation.siemens.com/WW/view/en/44231658
We recommend regularly checking whether the selected lubricant is still approved

by Siemens.
BA 7300 EN 11/2010
14 / 17 Page 86
3. Check list for oil filling and oil change
Table 1: Oil-change check list
1 Oil-change record ready for completion? □ 21 Gear unit internal parts inspected for damage, □
repaired or replaced (if necessary)?
2 Sufficient fresh oil available? □ 22 Gear unit and oil supply system with pipework □
flushed out (if necessary)?
3 Sufficiently large oil collector and used oil □ 23 Oil filter cleaned or replaced □
receptacle(s) available? (if necessary)?
4 Sufficient oil binding and cleaning materials □ 24 Seals changed? □

available?
5 Sufficient room available for oil change? □ 25 Opened vent and drain points closed again? □
6 Oil samples (used and fresh oil) taken and □ 26 Cause(s) of leaks removed (see item 10)? □
stored?
7 Protective clothing (glasses, gloves, etc.) □ 27 Fresh oil visually checked? □

available and used?
8 Oil change by specialist personnel? □ 28 Oil filling hole(s) opened? □
9 Gear unit and/or oil supply system □ 29 Fresh oil put in through filter up to mark on the □
manufacturers’ maintenance instructions read? oil-level check point?
10 Leaks in the drive and/or output recorded after □ 30 Oil-filling hole closed? □
visual check?
11 Used oil at a temperature of between 30 and □ 31 Drive started and run for a short while □
50 °C and drive started? (approx. 10 minutes)?
12 Drive shut down and prevented from □ 32 Oil level checked □

restarting? (after min. 15 minutes rest time)?
13 Vent hole opened? □ 33 Oil topped up or drained off until the oil level is □
correct (if necessary)?
14 Oil collector placed under the oil drain? □ 34 Oil-change record completed? □
15 Drain opened carefully? □ 35 Sample of used oil checked? □

Caution risk of scalding!
16 Used oil completely drained off? □ 36 Used oil correctly disposed of? □
17 Ancillary units, oil pockets and pipework □ 37 Sample of new operating oil taken after □
emptied (if any)? approx. 5 hours and stored
(for checking when changing type of oil)?
18 Spilled oil immediately bound with suitable □ 38 Binding material and cleaning cloths correctly □
material? disposed of?
19 Used oil assessed and recorded? □ 39 Drive restarted? □
20 Gear unit and other units thoroughly cleaned? □ 40 Filter checked and cleaned or replaced □
(after one week’s operation at most)?
BA 7300 EN 11/2010
15 / 17 Page 87
4. Documentation sheet for oil change
Table 2: Oil-change oil-filling record
Oil-change oil-filling record

System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear unit: . . . . . . . . . . . . . . . . . . . . . . .
Date: . . . . . . . . . . . . . . . . . . . . . . . . . . Operating hours: . . . . . . . . . . . . . . . . . Last oil change . . . . . . . . . . . . . . . . . . .
Oil to be used Quantity

according to rating plate: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . according to rating plate: . . . . . . . . . .
Condition before oil change
Designation of oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil level: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear unit/oil supply system leaktight? yes □ no □ Filter dirty? yes □ no □
Operating temperature: . . . . . . . . . . . °C
Other noticeable features: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.......................................................................................................
Used oil
Identification mark of used-oil sample: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Laboratory number: . . . . . . . . . . . . . . .
Quantity: . . . . . . . . . . . . . . . . . . . . . . . .
Result of visual check of oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear unit / oil supply system
Deposits? yes □ no □
Fresh oil
Designation of oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Designation of fresh-oil sample: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Laboratory number: . . . . . . . . . . . . . . .
Filtered during filling? yes □ no □ Filter mesh: . . . . . . μm Quantity put in: . . . . . . . . . . . . . . . . . . .
Was/were the gear unit and/or the oil-supply system flushed before being filled with fresh oil?
yes □ with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . no □
Noticeable features (if applicable): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.......................................................................................................
Designation of 5hour operating oil sample: . . . . . . . . . . . . . . . . . . . . . . . . . . . . Laboratory number: . . . . . . . . . . . . . . .
Name of recorder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Department: . . . . . . . . . . . . . . . . . . . . .
Date: . . . . . . . . . . . . . . . . . . . . . . . . . . Signature:
BA 7300 EN 11/2010
16 / 17 Page 88
Siemens AG Subject to modifications
Industry Sector
Mechanical Drives © Siemens AG 2010
Alfred-Flender-Straße 77
46395 Bocholt
GERMANY
www.siemens.com/drivetechnology
Page 89
OPERATION & MAINTENANCE MANUAL
FOR
OIL SUPPLY SYSTEM
Page 90
CENLUB SYSTEMS
OPERATION AND MAINTAINANCE MANUAL
FOR
OIL SUPPLY SYSTEM- 110 LPM-22700 KCAL/HR
CUSTOMER: M/S SIEMENS INDIA LIMITED
P. O. NO: 4507706592 Date:-18 AUG 2017
O.A. NO. : A181085
CENLUB SYSTEMS
42, D.L.F. INDUSTRIAL ESTATE-1
FARIDABAD –121003 (HARYANA) INDIA
PH. NO. : 91-129-4113772/71/2255180
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Part 1
System Description
This Manual is intended to familiarize the user with Oil Supply System (OSS) & its constituents and to enable them to
use its various features. This manual must always be available at site / location where the OSS is in Operation. In
case the persons who are in charge of the OSS do not have a good command on English language it is the user's
(Owner's) responsibility to take the necessary action to make this manual understandable to those persons. This
manual is concerned the situations which, according to our experience, are the most likely to occur.
• OSS consist of Pump with electric motor,Duplex filter and heat exchanger with required ball valves, non
return valves, globe valve, pressure Switch, temperature Switch, pressure gauge, differential pressure switch,
flow switch and all the above components are connected by steel pipeline with necessary fittings as per the
drawing (CS G.A DRG NO-2YLMB-479). Place the system at the nearest possible location to the equipment,
to be lubricated. Connect the pressure line and return line of oil to the equipment & also water lines (both inlet
& outlet of water line) of cooler.
General Specifications:
System working pressure - Up to 2 bar

Flow rate - 110 LPM
Fluid Medium - ISO-VG-460
System Suction Size - 50 NB
System Delivery Size - 40 NB
Filtration level - 60 Micron
Water Inlet Temp - 32 ºC
Oil Inlet/Outlet Temperature - 75/67 ºC
1. Main power supply - 460V AC-50HZ-3Phase
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Part -2
System Construction
a) BALL VALVE
3nos. of Ball valves is installed in the system in suction line.Its function is to start or stop flow, and when a straight-line
flow of fluid and minimum flow restriction are needed.
b) PUMP
Rotary gear pump of Rotodel make is used for pumping oil from the main sump to the distribution line. Two nos. of
pump are provided in the system. At a time one pump will be working and other will be in stand by mode.
c) MOTOR
Motor acts as prime mover to the pump. It is coupled to the pump with the help of flexible coupling. There are given 2
nos. of motor. When first is working second motor is in stand by mode and provided for continuous duty.
d) DUPLEX FILTER
One Duplex Filter is provided in the systems for the filtration of oil. At a time one filter is working and the other is
standing by.
e) DIFFRENTIAL PRESSURE SWITCH
Diff. Pressure switch is a safety device which is incorporated in the system so as to send electric signal to the
JB/Control Panel in case pressure difference across the filter exceeds the desired set limit.
f) ISOLATION VALVE
For maintenance or replacement of pressure gauge, Pr. Switch and Diff. Pr. Switch, isolation valve provided.
g) OIL COOLER
During circulation the oil gets heated as it picks up heat from the rotating bearings etc. Oil cooler cools the heated oil
& allows cooled oil to re-circulate through the lube points. One set of oil cooler are provided in the system.
h) CHECK VALVE (NON RETURN VALVE)
Two nos. of check valves are mounted on the Pump Outlet to prevent oil return back into pump.
i) PRESSURE GAUGE
Pressure Gauge is provided in the system for monitoring the system pressure. 1 nos of pressure gauge is mounted in
system.
j) PRESSURE SWITCH
Pressure switch is a safety device which is incorporated in the system so as to send electric signal to the JB/Control
Panel in case pressure in the system exceeds the desired set limit. One no of Pr. Switch is given at delivery line in the
system.
k) TEMPERATURE GAUGE
To check the temperature of oil at outlet one Temperature Gauge is Provoded.
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l) FLOW SWITCH
Flow Switch is installed on the discharge branches line to send the electric signal to the JB/Control Panel in
case of oil low flow in the system.
m) GLOBE VALVE
Globe valve is provided in the system for bypass of flow.its function is to give the regulating flow in a pipeline, it
consist of a movable disk-type element and a stationary ring seat in a generally spherical body.
n) TEMPERATURE SWITCH
To control in line temperature of suction oil one temperature Switch is being provided on Suction Line of the system.
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Part 3
System Working Logic
The system to be firmly grouted by means of foundation bolts. While installing the system should not be subjected to
any mechanical stresses. System shall be fixed as close to the equipment to avoid pressure drop & long running pipe
line. The pipelines shall not be subjected to any mechanical forces and must be supported in a manner ensuring that
leakage in the pipe joints cannot occur as a result of vibration. Provide tube clamps in the line to avoid vibration
transmission. Check the voltage & frequency of the electric motor. Check the rotation direction as indicated by the
arrow on the pump. Complete electrical connections of the system. Ensure proper connections from local JB /Control
Panel to central control system like DCS etc., No cables shall be left loose. Ensure use of proper glands and conduits
for safety purpose. Carry out piping connections between the lubrication system and the equipment to be lubricated
properly. Ensure that the return lines from the lubrication points are drawn with required slope. Ensure proper
clamping of supply and return lines to avoid vibration.
Now, the system is ready for initial start-up.
INITIAL START-UP & OPERATION
Initial Start up:
• Open the valves which are used before the pump similarly close the ball valves of stand -by pump.
• Open the valves which are used before & after the filter and heat exchanger.
• Tighten all the tube fittings & joints, which are done at site.
• Ensure no oil leakage through the line.
• The system is now ready for operation.
• Ensure electric source supplied for motor-460V AC-50HZ-3Phase.
• Check the direction of motor.
• Caution: Pump should not run dry.
Operation:
• Switch on the System.

• Ensure the Oil flow through the line.
• Now the system is ready for use.
• Start water flow into the heat exchanger.
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Part – 6
INSPECTION, SERVICING & TROUBLE SHOOTING
Introduction
In general the term "Maintenance" can be divided into the following three activities:
Inspection
Action taken to maintain the status i.e. ensuring that wear margins and reserves are used up to as slow a rate as
possible during the service life of the equipment
Servicing
Action to as certain the actual status i.e. determining how and why wear margins & reserves are being used up.
Trouble-Shooting
Trouble Shooting involves Repair & Fault Finding of a System.
MAINTAINING OIL LUBRICATION INSTALLATIONS:
The enormous variety of applications for oil lubrication means that the type of equipment encountered ranges widely
from the simplest unit incorporating perhaps one pump supplying one actuator to major complex installations
incorporating several pumps and highly sophisticated control units. The maintenance needed by these installations
must be planned and executed according to such factors as the required value of this installation, its usage
(intermittent, multi-shift or continuous) and the consequences of a break down (an individual unit performing some
subsidiary task or an important sub-system which would result in the shutdown of a whole line)
INSPECTION:
The individual point of a particular installation requiring inspection should be put down "inspection lists" so that it is
possible for them to be attended with adequate thoroughness by persons of different level of skill. In the case of large
installation there will be different inspection points according to different periods of service i.e. daily inspection points,
monthly inspection points and inspections shortly before an extended shutdown e.g. holidays.
The principal inspection points are as follows:
CHECK TANK FLUID LEVEL
A low fluid level is usually indicative of a loss of fluid through external leakage. After major repair work the fluid level
can sometimes continue falling slowly for sometime as the system automatically bleed itself of air. A high fluid level
can be indicative of parts of the system at a higher-level draining while shut down due to the ingress of air Water can
gain access to the oil system through leakage in water fluid heat exchangers.
CHECK FOR EXTERNAL LEAKAGE (VISUAL EXAMINATION)
Examine all rigid pipes (particularly the connectors), pumps & valves.
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CHECK PRESSURE SETTINGS
Check the operating pressures of pressure relief valves and unloading valves.
CHECK LEAKAGES RATES
With valves and some hydraulic pumps it is possible to assess the internal wear by measuring the leakage fluid rate.
This also applies to a number of control valves and check valves.
CHECK THE FLUID PURITY
A visual examination will only provide a rough estimate of the condition of the fluid i.e. cloudiness, darker appearance
than new fluid in the fluid tank. There are three methods of measuring the purity accurately: Gravimetric determination
of solids by the filtering of a certain quantity of fluid (e.g. 100 NW) and weighing of the filter paper before and after
filtration. This will give a figure of solids content in /mg. However, the actual solids content will be somewhat higher
than the figure recorded because even very fine filter papers have an average pore size of about 08m although very
fine contamination of this size will not actually cause any wear at normal mechanical fits, it can contribute to erosion in
places where the fluid velocity is very high (e.g. in pressure relief valves, grooves in control valves etc.). The
gravimetric method also says nothing about the composition of neither the solids nor anything about the size
distribution Gravimetric analysis can only be performed in laboratory or in a laboratory van specially equipped for fluid
analysis. Particle counting by electronic counting and sorting devices Such devices can function fully automatically
However, fluids containing water, these devices cannot analyze mixtures of fluids and fluids with excessive solids
content As they are very costly, they are normally only found in the laboratories of large companies, filter
manufacturers & fluid suppliers with suitable calibration, the results can be directly compared with the contamination
classes of NAS or SAE standards.
MICROSCOPIC ANALYSIS:
In this case a few precisely - measured drops of fluid are placed on highly absorbent surface such as a filter paper
and the solids remaining on the surface after the fluid has been absorbed are counted under the microscope This
method also allows an assessment of the size of the particle distribution and rough estimate of composition e.g. metal
particles, seals residue, silicate, fibers etc It is a method that allows a quick analysis to be made on site, where the
other methods described can only be performed in the laboratory or in special equipped vans.
CHECK FOR FILTER CLOGGING
A visual check of the filter elements, which is in widespread use today, will reveal nothing. The amount of clogging
can only be determined by measuring the pressure drop across the filter element so that such checks can not be
performed without the required instruments, the filters used In the system should always incorporate a visual-clogging
indicator for clogging Solids in the fluid are the main cause of wear in hydraulic components.
The amount of solids smaller than the pore size of the filters used in the system is also significant factor because they
provide erosion and through a kind of lapping, increase spool clearances, wear away control surfaces and ruin
dynamic sealing elements Sudden equipment failure is a rare occurrence but the actual service life of the component
is reduced to a fraction of the design value.
CHECK THE CHEMICAL PROPERTIES OF FLUID
It is inevitable that the chemical stability of fluid will be affected to some extent in time by the severe stress.
Placed upon it by such things as pressure fluctuations, high velocities, high shear loads, localized overheating,
absorption of oxygen from the air, contact with various metals, elastomers and plastics and the absorption of
condensation and solid particles. Consequently, regular tests should be made on the neutralization number (soaping
number), oxidation product content, viscosity and viscosity index. The tests are more important for mineral oil fluids
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and so should be performed more frequently because it is constantly being proven that major damage can be caused
by chemical changes, which take place very
rapidly although outwardly everything appears satisfactory, and in order If the user of the system does not have his
own laboratory, an agreement can usually be made with the fluid supplier to perform the tests on regular basis when
there is only a relatively small amount of fluid involved it is probably cheaper and simpler to change the fluid
periodically in order to avoid the on-going expense of chemical tests.
CHECK FOR NOISES
In this case too the object is to detect changes from the status quo when the equipment was new. Pressure relief
valves normally make a hissing noise when they lift.
An increase in hydraulic pump or major noise with increasing pressure can be indicative of erosion or cavitations
damage to control surfaces, excessive clearance in displacement elements or incipient bearing damage. Unpleasantly
loud noise from pumps regardless of the pressure but gaining greatly in intensity as the speed rises is a signal for
insufficient boost pressure or excessive negative pressure in the suction line.
CHECK PIPES
Examine all pipes, connectors and fitting for leakage and ensure that the pipes are firmly supported everywhere. Links
and crush points increase the flow resistance causing loss of power and overheating.
In actual practice the division between inspections, servicing and repair are not as strict as definitions would suggest It
is common, e.g. for servicing to be carried out at the same time as inspection.
SERVICING
The main servicing work involves:
TOPPING UP THE FLUID
The fluid with which the system is topped up should always be the same as that already in the system. This is a
particularly important point to note in the case of mineral-oil-fluids from different manufactures because they may
differ in base oil and additives.
CHANGING THE FLUID
Hydraulic fluid should be replaced as soon as any changes in its chemical properties start to take place e.g. the
presence of oxidation products increase in neutralization number or Soaponification number, disappearance of
essential additives, change in viscosity, etc. The fluid should also be changed when the fine contamination (i.e. the
content of solids smaller than the pore size of the system filters) has increased to a point where greater long-term
wear must be anticipated (e.g. over 250,000 particles between 5 and 15 mm per 100 ml) Expensive purification
processes such as centrifuging (if the type of fluid will allow) or filter
presses are only economical if the quantity of fluid is large Since the amount of fluid in the actual system, i.e. pumps,
pipes, control gear and cylinders, is sometimes several times more than the capacity of the tank it is not enough to
change just the amount of fluid in the tank This is especially true if the old fluid is already showing signs of chemical
instability.
The oil tank must be cleaned out every time the fluid is changed An important point to remember, both when topping
up and changing the whole quantity of fluid, is that new fluid as-supplied is not normally immediately suitable for use
in a hydraulic system due to the quantity of solids which it contains The chain of supply from manufacturer to end-user
is often very long, passing through storage tanks; sea and road going tankers, tank cars and various types of
container, and the required purity cannot be guaranteed.
Therefore, for topping-up and for complete renewal the new fluid must be passed through a suitable filter first Its pore
size must be at least equal to that of the filters fitted in the system but it is better to be smaller. This is a very important
13 A181085
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point requiring close attention otherwise there is a possibility of malfunctions immediately after the fluid has been
changed.
CLEANING THE FILTERS
Filter elements should also be cleaned or changed every time the fluid is changed With the types of filter fabrics in
widespread use today cleaning is not a practical proposition so the elements are changed The amount of clogging of
a filter element can only be discovered from the pressure drop across it since nothing can be seen with the naked eye
Without artificial aid, the human eye is only able to see particles larger than about 45 to 50 microns in size This means
that all filters used now should be the type incorporating a visual or electric clogging indicator showing when
maximum clogging has been reached Filters without such a monitoring device must be changed at regular intervals,
which should be short enough to ensure that the by-pass valve does not lift or the clogged element burst.
RE-ADJUSTING PRESSURES
Readjust all pressure settings - pressure relief valves in the working circuit, control circuit and low-pressure circuit.
DEALING WITH LEAKAGE IN THE PIPE WORK
Resealing work on the pipe line should only be performed with the system depressurized. Re-tightening because the
seals will either have broken or gone hard cannot eliminate leakage from fittings incorporating soft seals such as O-
rings. A new seal will have to be fitted in order to effect an improvement.
REPAIR
FAULT FINDING
Any repair to a system must be preceded by successful faultfinding
It requires a systematic approach, one of the basic necessities for which is the easy availability of all the relevant
documentation. It is desirable for a circuit diagram containing lists of components and a function sequence chart to be
kept constantly available close to the installation. Past experience has shown that it is an excellent idea to paste the
diagrams on to boards and then either varnish them or cover them with Perspex to prevent them becoming dirty or
damaged good lamination is also beneficial.
Important measuring instruments should also be available close by, especially on the larger installations
The most important corrective tools for a troubleshooter are pressure gauges of the necessary measuring ranges In
order to maintain accuracy and an acceptable service life, pressure gauges should normally be chosen so that only
2/3 to ¾ of the maximum scale reading is utilized It is important to re-seal the connecting points afterwards with the
screw caps to keep out dirt and to protect the sealing surface.
THERMOMETERS:
(Electronic thermometers with surface sensors are best)
- For quickly finding points of high temperature due to leakage, power loss, etc.
Naturally there are also many other specialized measuring instruments available on the market for measuring voltage
and current, which have been specifically designed and are very easy to use.
INDUSTRIAL STETHISCOPE
- For pin-pointing noise sources through structure-borne sound
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TACHOMETER:
- For measuring the speed of motors
MEASURING FLOW RATES:
The electrician has an easy task measuring current compared with the hydraulic engineer trying to measure flow rate.
The system has to be opened up in order to fit a flow meter, so that may be avoided from the danger of fluid
contamination and fluid loss.
Only few instruments are able to withstand the pressures involved and the measuring range is often relatively small
consequently, the hydraulics engineer usually has to measure flow rate indirectly through and the speeds of hydraulic
motors.
STANDARD TOOLS
FAULT RECTIFICATION
Generally speaking, faulty equipment should not be repaired on site because neither the necessary tools nor the
necessary cleanliness are normally available there. Whenever possible the procedure should be to change complete
items or sub-assemblies locally in order to :-
- So that the system is only opened up for as long as is absolutely necessary

- So that fluid loss is kept to a minimum
- So that the down time is kept to a minimum by using overhauled and pre-tested equipment another very important
factor after the failed item of equipment has been pinpointed is to ascertain whether the failure has caused any
contamination of the remainder of the system due to broken pieces of metal or large quantities of metal residue.
If inspection of the filters or tank reveals such contamination, it is absolutely essential for the whole installation to be
cleaned, e.g. by flushing, before it is returned to service. The filter elements should also be changed and, depending
on the particular type of installation, it might be necessary to change the fluid
In the case of larger installations the fluid can be cleaned either by filter or centrifuge this is the only way of preventing
further malfunctions and the possible failure of other components due to secondary damage.
As an extra safety factor, particularly with sensitive systems which have to perform very precise control functions, it is
sensible to fit the filters, for a limited period of time (e.g. until they reach their clogging limit), with elements of the next
smaller pore size This is nearly always possible with modern filters when a system has been returned to service after
repair it should be kept under close observation for some time in order to be certain that the repair has actually
eliminated all the problems. Sometimes there is some irregular operation for a period if part of the system has not
been properly bleed of air, e.g. pumps give off loud knocking noises, etc.
CHECK VALVES
Generally all types of check valve have metallic seats and the cone is harder than the seat in the body.
The main problems with this type of valve (non return valves) are:
- Hardened seats They can be easily changed, great care must be taken when opening up the body because the
springs inside are sometimes very strong, internal leakage due to damaged valve seats Foreign objects or erosion
generally always causes such damage. A repair can be affected either by re-machining the seat or by changing both
seat and cone
The re-machining of body seats needs absolute precision, because misalignment between seat and guide may be
allowed. A static leakage test is easy to perform.
15 A181085
Page 100
TROUBLE SHOOTING - GENERAL GUIDELINES
Sr. No. ITEM TROUBLE REASONS

Low oil level in the reservoir, insufficient oil
No / insufficient
supply to the suction port/suction strainer,
pump
clogged Internal leakage in the pump Wear
flow
out of component due to dirt, wrong
direction of rotation, improper assembly.
1. Pump Excessive drive speed, wrong sense of

Excessive noise
rotation, Faulty sealing, Air entering in
suction, Damaged bearings, improper
assembly units
Insufficient
Internal leakage due to worn out parts
System pressure
improper seating of valves
Defective pressure gauge, Air lock, Faulty
2. Pressure gauge No/insufficient reading gauge isolation valve, any leakage in
system
3. Filter Exclusive Noise Low filtering capacity, Faulty attachment
Dry or damaged bearing, Improper
4. Electric Motor Excessive noise assembly of rotor, fan, cover etc. Single
phasing
Unwanted particle of anything in valve,
Throttle & Check
5. No / insufficient flow Internal leakage, Ball worn out, Improper
valve
setting
GENERAL CHART OF SYMPTOMS, CAUSES AND REMEDIES OF TROUBLE IN

CENTARAL OIL CIRCULATION SYSTEM
Sr. No. SYMPTOM CAUSE REMEDY

Use oil of desired viscosity, Clean
inlet screen, Pour oil over joints with
Cavitations Restricted suction
pumps, running and spot the joints
6. Noisy pump Air leak at intake pipe
and tighten Lubricate or renew
Connections Air leak at shaft
packing, accurately alignment of
pump & motor shaft
Bleed the air , renew worn parts such
Air trap in pump
7. Excessive heating of pump as, impeller, vanes, '0' rings, valves,
Internal leakage
etc.
Diminished or insufficient Pump parts worn out or Check consistency of oil, after that
8.
delivery of pump oil thickened by impurities check air gap.
Oil viscosity too high Use oil of desire viscosity or oil as
9. Erratic & sluggish operation
Insufficient power specified by manufacturer
Diminished delivery Check seal between inlet & outlet
10. Short circuit in pump
pressure of pump ports of pump
Release air from system, check
Provide for air vent, bleeder pressure relief valve, inspect suction
11. Unsteady pump pressure
coil or air cock in the system Line for obstruction & check efficiency
of pump
Check condition of valve seat if seat
or ball is in poor condition reset new
12. Check valve troubles Worn out seat or ball
ball by tapping against seat with soft
brass rod
16 A181085
Page 101
Relieve pressure control spring, start
Functioning pressure of
13. Accumulated dirt pump & let oil wash out accumulated
relief valve
dirt Check for proper adjustment
Lever or cams not in proper positions
Trouble with pressure Oil too heavy or too cold to start
14. Dirt or any impurities
switches Broken or weakened springs, dirt
causing piston to stick
WHAT DOES DIRT DO TO OIL LUBRICATION SYSTEM COMPONENTS

The dirt is responsible for a majority of malfunctions and unsatisfactory Component performance. Here is what dirt
does to components:
Check valves
Causes wear on ball and seats creating leakage Dirt in valves permits fluid to by-pass the check valve.
Pumps
Erodes wear plates Causes sticking of vanes creating erratic action. Causes the valves to wear out the cam ring
wears out rotor slots, increases shaft journal and bearing wear Increases impeller wear with resultant inefficiency Dirt
in compensator controls on variable volume pumps causes sticking, slow response and erratic delivery thus affecting
the performance of the entire system, creating excessive heat and insufficient use of HP.
Valves
Causes chatter Accumulated dirt causes valves to fail safe and pressure becomes erratic, which effects functioning of
entire system.
Fluid
Acts as a catalyst and breaks down molecular structure causing gummy residue varnish Dirt in the tank attracts
additives and changes composition of the fluid.
System
The system's malfunction due to dirt can result in serious damage to equipment, safety hazards, scraping of parts due
to poor finishes, insufficient pressure as well as higher hydraulic fluid costs which resulting increase in disposal
problems.
17 A181085
Page 102

IND
DEX
1 Index For Testt Certificcates of Lub
1. L unit
2 In-Coming Insspection
2. n Recordss:
Test Certificat
C ub unit Componeents
tes of Lu
[Arran
nged in order,
o ass per SLII LOE]
3 In-Pro
3. ocess Insspection Records:
a. Raww Materiial Test Certifica
C tes
b. Pip
ping Hyd dro Test Certifica
C ates
c. Surrface Preeparation
n & Paintting Reco
ords
4 Final Inspectio
4. I on Recorrds:
a. Dim
mensionaal Reporrt
b. Run
n Test Reecord
Page 103

INC
COMING IN
NSPECTIO
ON RE
ECORD
DS
Page 104
Page 105
Page 106
Page 107
Page 108
Page 109
Page 110
Page 111
Page 112

GEA
AR PU
UMP TC
Page 113
Page 114
Page 115

T
THREE-PHASE E
ELECT
TRIC MOT
TOR TC
Page 116
60 Hz+/-5%
Page 117
60Hz+/-5%
Page 118

DUP
PLEX BASK
B KET FILTER
R TC
Page 119
Page 120

OIL
L COO
OLER TC
Page 121
Page 122
Page 123
Page 124
TETEST CERTIFICATE
Page 1 of 1
Date 16-Oct-2017
Customer Cenlub Systems
Plot No 42, DLF Industrial Estate,
Phase-1
Faridabad 121003
PO No. PI-182515
Invoice No. MS/17-18/0394 DT 16/10/2017
We hereby certify that the products mentioned hereunder referring to above PO No. and Invoice No.
have been inspected and approved for dispatch.
Sr. Description Range Part Qty

1 Temperature Switch 80-150 deg c KP 81/ 060L118366 2
2 Pressure Switch 0.2-3 bar RT 110/ 017-529166 2
3 Diff. Pressure Switch
(-)1 to 9 bar RT 262A/ 017D002566 2
4 Sensor Pocket NA 060L327166 2
TOTAL QUANTITY 8
We further confirm that the products are in conformity with the following norms and conditions Low
Voltage Directive 2006/95/EC
EN 60947-4-1
EN 60947-5-1
RoHS Directive 2002/95/EC with amendment 2005/618/EC
Issued by: Ginu Sasidharan Date: 16-Oct-2017
The quality of Danfoss products is constantly monitored and controlled through the Danfoss quality
assurance system, which is certified in accordance with ISO 9001. A description of the quality assurance
system, and the scope of registration can be obtain
INDUSTRIAL CONTROLS
Page 125

PRESSU
URE GAUG
GE CU
UM SW
WITC
CH TC
C
Page 126
Page 127
Page 128
Page 129
Page 130

TEMPER
RATU
URE GAUG
G GE CU
UM SW
WITCH
H TC

Page 131
Page 132
Page 133
Page 134
Page 135
Page 136
Page 137
Page 138
Page 139
Page 140
Page 141
Page 142
Page 143
Page 144

FINAL
L INSP
PECT
TION RECO
ORDS
Page 145
Page 146
Operating Manual / Instruction for
other Components
Page 147
PART 7
COMPONENT MANUAL
• Pump
• Electric Motor
• Duplex Filter
• Differential Pressure Switch
• Oil Cooler
• Pressure Gauge
• Pressure Switch
• Temperature Gauge
• Flow Switch
• Temperature Switch
18 A181085
Page 148
INSTALLATION & MAINTENANCE GUIDELINES
FOR GLOBE VALVE
TECHNICAL DATA
MANUFACTURING STANDARD : BS 1873 / BS 5352
FACE TO FACE : ANSI B 16.10
END CONNECTION : ANSI B 16.5 RF / ANSI B 16.25
INSPECTION & TESTING STANDARD : BS 6755
SERVICE – FLUID
INSTALLATION
Globe valves should be installed where an adequate space is available so that they
can be conveniently operated and maintained.
Before installing a valve, check to ensure that the size, pressure rating, material of
construction, end connections, etc; are suitable for the service conditions of the
particular application.
Care must be taken to ensure that the dirt, which might have accumulated in the
valve during storage, is removed before the valve is installed. Maintain cleanliness
during installation since the insertion of dirt can result in damage to the valve seats
and operating mechanism.
Slag spatter should be avoided, as its presence is detrimental to the performance of
the valve.
Valves should be handled by valve body and by lifting lug only.
Although valves are tested prior to despatch it is possible that some adjustment
may be necessary, for instance to the joint packing, when the valve is on stream.
MAINTENACE
With all the mechanical devices regular maintenance is the most efficient factor to
ensure continued operational efficiency.
Regular scheduled inspection of all valves is essential.
Valves having body bonnet joint packing should be inspected frequently to check
that the pressure seal is being maintained. At the first sign of leakage, the jointing
bolts & nuts should be adjusted.
Examine valve disc and seating to ascertain the extent of any damage or services
wear, either reconditions on site or return to the manufacturer.
Cover and flange gaskets should be inspected and replaced where necessary.
TROUBLE SHOOTING AND REMEDIES TO COMMON PROBLEMS
TROUBLE: Leakage from joint.

REMEDY: Tighten the bolts. Alternatively replace the Gasket.
TROUBLE: Leakage from Disk and Seat Ring.

REMEDY: Lapping should be done. Alternatively recondition the valve.
Page 149
FOR
ROTARY TYPE TWIN GEAR
Pump Type :RDRN
Page 150
1. INTRODUCTION :
The rotary pump is one of the most versatile & widely used type pump. Where
mechanical displacement of the fluid from inlet to outlet is produced by trapping a slug of
fluid between one or more moving element such as gears, Cam, screw, vanes, lobes or
other similar device within a stationary casing, The rotary motion of the centrifugal pump
is combined with the positive characteristics of the reciprocating pump.
Gears pump is a self-priming positive displacement pump in which two or more
gears mesh to provide the pumping action. It is the characteristic that one of the gear be
capable of driving the others. The mechanical contacts between the gear and the outer
radial tip and sides of the gears form a part of the moving fluid seal between the inlet &
outlet posts.
Gears pumps are of two types external & internal. The pumping element is a set of
spur., helical of herringbone gears which rotates in a closed housing. External gear pump
are arranged in such a way that the center of rotation of each element is external to the
major diameter of the external tooth. Here the gear tooth gap closed by casing forms a
bucket, which bodily carries the liquid from suction port to the discharge port on its pitch
circle diameter.
Unlike in centrifugal pump, positive displacement pump does not develop pressure
on its own but it overcomes the resistance in the pipeline while discharging a rated
capacity. Due to some working clearance between the rotating element and the casing
some amount of liquid always tends to leak away from the discharge side to suction side
termed as slip which depends on the working clearance and workmanship, liquid
viscosity and the differential pressure, when the slip is more than the specified or when
there is a substantial drop due to slip we say that the positive displacement pump is not
developing sufficient pressure.
No pump can suck the liquid on its own but the liquid is placed in the pumping
chamber with the assistance of atmospheric pressure due to creation of vacuum in the
pump suction chamber by displacement of the air of the pumping liquid. Because of the
closed tolerance between the rotating & stationary parts and due to the viscous nature of
pumping liquid, film formation is possible helping in creating vacuum in the suction
chamber when the pump is started thus gear pump have a self priming capability like
piston pumps.
"ROTODEL" rotary gear pumps are the most updated version in gear pumps, where
advantage of both gear and screw pumps are combined most judiciously, The compact
size, efficient and reliable performance & widest range makes a wise decision to install a
”ROTODEL” pump.
2. POSITIVE DISPLACEMENT ROTARY PUMP CHARACTERISTICS :.
2.1 SUCTION PRESSURE & NPSH REQUIREMENT :
The identification of the pump suction pressure requirement is significant in any

pump application. Specifying a higher suction lift than actually exists, results in selection
of pump at a lower speed than necessary. Not only this does mean a larger, more
expensive pump but also a costlier driver. Should the suction lift requirement be higher
than specified, the outcome could be a noisy installation due to pump cavitations.
There is a common misconception that pumps ”pull” fluid into the inlet opening
unassisted by any outside force. Actually, fluid flows into the pump due to a difference in
pressure between pump inlet and the fluid source. A primary step in pump Positive
Suction Head (NPSH), This is the absolute pressure above fluid vapor pressure at pump
Page 151
inlet and is determined as follows :
1. Atmospheric pressure (at jobsite altitude)
2. Plus Static head (minimum level of fluid below pump inlet)
or
Minus inlet line friction losses including entrance loss from reservoir to pipe, pressure
drops through valves, fitting, strainers etc.
4. Minus fluid vapor pressure (usually at max. pumping temp)
5. Equals system Net inlet Pressure. System Net inlet pressure available must always equal
or exceed pump Net inlet pressure required. Suction condition. is the most frequently
overlooked parameter in pump selection. Time spent determining it accurately can
optimize pump selection and result in a quit installation.
2.2 PUMP HORSE POWER & EFFICIENCY :
The brake horsepower required to drive a rotary pump is the sum of the theoretical
liquid horsepower and the internal power losses. The theoretical liquid horsepower is the
actual work done in moving the fluid
from its inlet pressure to the outlet at discharge pressure. This work is done on all the
fluid of theoretical capacity not just delivered capacity, as slip does not exist until a
pressure difference occurs. Rotary pump power ratings are expressed in terms of
horsepower (550 ft-lb/sec) and theoretical liquid horsepower is calculated.
tLhp = Qt P / 1714
Note that theoretical liquid horsepower is independent of viscosity and is concerned only
with the physical dimension of the pumping elements, the positive speed and differential
pressure.
The internal power losses are made up of two types : mechanical and viscous, The
mechanical losses include all power necessary to over come the mechanical friction drag
of all the moving parts within the pump, including bearings, gears, mechanical seals etc.
The viscous losses include all the power lost from the shearing action of the fluid itself. It
is probable that the mechanical loss is the major component when operation at low
viscosities and high speeds, while the viscous loss is the larger at high viscosity and slow
speed conditions.
TH E O R ITIC A L
5 0 0 SS
U
200 V O L U M E TR IC
S SU LO S S E S A C TU A L
AL
C A P A C ITY
C A P A C ITY
IC
O R IT
HE S U
A C TU A L T 0 S SU
50 0 S
20
A C TU A L
P O W E R C O N S U M P TIO N
P O W E R C O N S U M P TIO N
SU
H Y D R A U L IC H P + 0 S 0 S SU
50 20
V O L U M E TR IC L O S S E S
TH E O R ITIC A L
P O W E R C O N S U M P T IO N F R IC T IO N A L L O S S E S
A T N O LO A D = + M E C H A N IC A L L O S S E S
D E F F E R N TIA L P R E S S U R E SPEED
Page 152
Volumetric efficiency, Ev = Qc / Qt
Overall Pump Efficiency, Eop = OHP / BHP
Where OHP (oil horse power) - Pc p / 1714
Mechanical Efficiency, E = Eop / Ev
Where Qc = delivered capacity, GPM
Qt = theoretical capacity, GPM
P = differential Pressure PSI
Looking at the curves, one can see that theoretical capacity is directly proportional to
speed and is constant regardless of differential pressure, The difference between
theoretical capacity and delivered capacity is the slip of the pump for a given viscosity.
Depending on design, slip can be affected by speed, pressure and viscosity.
Since HP = GPM x P / constant, both horsepower curves increase as speed (capacity) or
differential pressure increases.
2.3 EFFECT OF VISCOSITY :
Viscosity is that property of any fluid (liquid of gas) which tends to resist a shearing
force. It is important to fluid flow because nearly all fluid motion is accompanied by
shearing force.
The two basic viscosity parameters are the Dynamic (of Absolute) Viscosity, u,
having the dimension force x time / length2 and the kinematics Viscosity, V, having the
dimension force x time / length2. The parameters are related through the mass density of
the fluid, Y, such that V = wp = g/y, where y is the specific weight and g is the
acceleration of gravity, The dynamic viscosity of any fluid is a function of temperature and
pressure.
The dynamic viscosity of most liquids increases with increase of pressure but,
fortunately the changes may be neglected for the ranges of pressure usually encountered
in engineering problems.
However, it is important to note the effect of viscosity on horse power. the difference
between actual horsepower and theoretical horsepower for given viscosity is the
mechanical loss and slip. Mechanical loss is primarily the loss increases with increasing
speed and viscosity and may or may not be dependent on differential pressure.
2.4 VISCOSITY CONVERSION FACTORS AND FORMULAS
M u l t ip l y by t o o b t a in
P o is e s 100 c e n t ip o is e s
p o u n d - s e c o n d s / s q . f t. 4 7 ,8 8 0 ,1 c e n t ip o is e s
Re yn s 6 .8 9 4 7 3 x 1 0 + 6 c e n t ip o is e s
c e n t ip o is e s 2 .0 8 8 6 5 x 1 0 -5 p o u n d -se c o n d / s q . f t.
c e n t ip o is e s 1 ,4 5 0 3 8 x 1 0 -7 Re yn s
s t ro k e 100 c e n t ip o is e s
S q . f t. / S e c o n d 9 2 .9 0 3 .4 c e n t ip o is e s
c e n t is t o k e s 1 .0 7 6 3 9 x 1 0 -5 S q . f t. / S e c o n d
S q . f t. / s e c o n d pound s
1 4 8 8 x y in c u . f t. c e n t ip o is e s
6 .7 1 9 7 0 x 1 0 -4
C e n t ip o is e s S q . f t. / S e c o n d
y in p o u n d s / c u . f t.
Kinematics Viscosity (in Centistokes) = Absolute Viscosity (in Centipoises)

Specific Gravity
Above 300 SSU use the following approximate conversion SSU = Centistokes x 4.635
3. PROPER ALIGNMENT & INSTALLATION
All rotary pumps are required to couple with a prime mover to impart rotary motion to
4
Page 153
the rotors which in turn develops the desired flow of the liquid. Hence it is always
necessary to the pump with prime mover to match the rated speed of the pump to get the
correct capacity.
Based on the pressure requirement to the pump adequate horsepower of the drive
should be selected to avoid overloading. As rotary gear pumps are closed tolerance
pump and in many cases with journal bush bearing, perfect alignment of pump & motor
shaft is warranted.
Slightest misalignment can cause greater wear of coupling, bushes, bearing and seal
faces. Factory coupled ”ROTODEL” pumps are perfectly aligned on duly machined base
plate with the drive perfect alignment at e users and should ne verified prior to the
commissioning of the pumps as follow.
(1) Use hairline gauge & filter gauge on two levels staggered by 90 degree each at the
circumference of the coupling. In case A vertical, lateral of angular displacement is
detected under the two coupling halves, the driving are in alignment (to be leveled by
plain parallel supports. if necessary) the gap between coupling halves must be to same
size around the coupling circumference. The distance from the hairline gauge placed
over both the coupling halves, to the respective shaft must be same over the entire
circumferences.
(2) Alternatively, the radial and axial alignment of the coupling can be checked with dial
gauge, This measuring method is applied in case of coupling with spacers (dismantling
type coupling)
NOTE : The maximum admissible axial and radial deviation, measured on the coupling
front side or at the coupling circumference may be 0.1 mm. if possible, however, less
than or equal 0.05 mm.
After aligning it is possible to rotate the pump with driving motor by hand without any
pressure points.
For perfect alignment it is also equally important to use a properly machined base
plate. The coupled pump should be installed fixed with the help of minimum one foot
depth and should be fixed with the help of minimum four numbers of foundation bolts.
While fixing up the pipe care should be taken that there is no direct stress and stain on
the pump flanges particularly in case of pumps with threaded port. Care should be taken
to ensure that the threaded pipe do not struck with the rotor gears.
Installation of suction line is the most important as perfect working of the pump
entirely depends on the perfect suction line. Ensure that the NPSH available at the pump
inlet is more than that required by the pump as specified by the manufacturer, To
increase the NPSH availability always use one size higher suction line with use of an
eccentric enlarger as shown below. It is also advisable to put a “U” bend between the
pump inlet and the enlarger to avoid the priming failure. More number of bends valves,
throttles should be avoided. If suction strainer is provided ensure that it has adequate
filtering area to avoid rapid clogging. There should not be any air leakage whatsoever in
the suction line.
Page 154
.
4. OPERATION AND PRESERVATION

After correct installation, before starting the pump for the first run, care should be taken to
ensure that the pump don’t get damaged following points should be checked before
commissioning.
(1) Check free rotation of the pump, The pump may be running jammed for the following four
reasons.
A. Suction . discharge line (in case of threaded ports) rubs the gear.
B. Foreign particles like small pebbles, weld entrapped in the pump.
C. The alignment is not perfect.
D. Pump not used since long time.
Take corrective steps as per trouble shooting chart and make pump free (Section-9.3)
(2) Ensure that all the joints on suction line are airtight and the suction pipe is thoroughly
cleaned & does not have any scales as this may cause damage to the pumping element.
It is always particles in the pump as it can damage the internals.
(3) Check the power connection and ensure that the motor runs in the right direction and is
connected to correct power supply.
(4) Thoroughly lubricate the pump by passing oil from air vent hole by opening plug and
rotating the pump with hand will make pump free from rust.
In case of prolonged shut-down. the pump must be protected against corrosion.
(1) Outside preservation : all bright and unvarnished parts such as drive shaft end, coupling,
flange facing, valve connection etc. must be protected against corrosion.
(2) Inside preservation : Close the suction end connection with the help of a dummy flange.
Full-up pump casing with lubricating oil. Care must be taken during filling, the discharge
flange must be on higher level than the suction flange. Crank the pump with hand so that
preservative reaches the casing rotor assembly, antifriction bearings, journal bearings,
pressure relief valves, mechanical seal. Continue filling process until the preservatives
reaches discharge flange, bubble free. Thereafter the discharge side is to be closed with
dummy flanges to prevent entry of dust and foreign particles. The pump should be
cranked once in a week. After prolonged storage all elastomers should be checked for
their elasticity.
Page 155
5. MAINTENANCE
5.1 PERIDOCAL :
(1) Alignment of the pump and motor must be checked as described earlier. At the same
time ensure that coupling key-way does not wear out (keep one should not feel angular
movement of the coupling. Repeat same for other halves), if found, replace coupling.
Tighten grub screws used to hold coupling halves over the shaft.
(2) Suction line must be checked for no air leakage. Also clean suction strainer and on line
filter, if used.
(3) Tighten all flange bolts and end cover bolts properly to ensure zero leakage.
(4) In case of pump with independently lubricated bearings (type RDRX & RDRXJ) the
bearing covers (02, 03) & pumping chamber is separated by viton ”V” seals hence
antifriction bearings are all the time immpresed in oil bath formed in back bearing cover &
front bearing cover is essential to maintain oil level in the chamber through out the
operating life of the pump.
(5) Check the oil level through oil level indicator, if found low fill up the same by unscrewing
bolt given at the top periphery of the bearing cover (02, 03) if any discriminative
properties are found in the oil, drain out the same by unscrewing drain bolt given on
faces of the front cover (02) & back cover (03).
(6) Put the pump into motion keeping make-up bolts open & observe if the oil is used away
fastly or it comes out along with the liquid to be handled then it gives indication to replace
the viton ”V” seal. If the same is available in spare then replace it in the next routine
maintenance (spare viton ”V” seal will be available from us on request. For that provide
us the pump model number engraved on the name plate)
(7) Periodically check the operation of Relief Valve by closing the gate valve on the delivery
side. The relief valve by closing the gate valve on the delivery side. The relief valve must
fully operate and by pass the liquid at set pressure specified in the test results.
5.2 YEARLY
For preventive maintenance purposes completely disassemble the pump once a year
with the view of checking the conditions of working surfaces of parts and to measure the
clearances between the gear faces and inserts.
1. Remove pump from base plate and check axial and redial play of the shaft with hand.
One should not feel axial or radial play. if axial play is observed replace wear plates and
if radial play is observed replace the bearings.
2. Check all elastomer parts (Lipseal Washer, mechanical seal for their elasticity and shape.
Disassemble pump (only expert person should do ) and check shafts (06, 08) wear plates
(05), gears (07, 09) casing (01) for wear and tear, if found, replace that particular
component. (Spares will be available from us on request.)
Page 156
6. REPLACEMENT OF PARTS :
6.1 ROTOR STATOR ASSEMBLY :

A. Remove the front cover (02) by unscrewing Hex bolt (16) and removing the dowel pin
(24) & also remove the back cover with the R. V. (03) by unscrewing hexbolt (17) and
removing the dowel pin.
B. The front side of the pump body is now open Try to pullout the rotor / stator by hand. If is
not possible to Pullout with hand. remove the back cover (03). with RV assembly (03)
Now slowly hammer the shaft end viewed in the back side.
C. Replace the old rotor / stator assembly with new one. Also check the conditions of wear
plates. If wear plates are not found in good conditions. replace it with new one.
D. After replacing the rotor / stator assembly in the body, first fix the back cover. Check
whether the rotor shaft is free for movement of jammed, try to make it free by slightest
radial movement.
E. Now fix the front cover & Gland cover or seal cover.
6.2 BEARINGS :
A. For removing bearing first remove the front cover and back covers as described in.
B. The bearing should be easily mounted by push fit and hammering should be avoided
which may result in premature failure of the same.
6.3 RELIEF VALVE :

A. For changing any relief valve component, the R. V. cover is not required to be removed
from the pump body.
B. The R. V. components can be disassembled as shown in the exploded view of R. V.
assembly. any part if found defective should be replaced with the new one.
7 SPARE PARTS :
7.1 ESSENTIAL FOR PREVENTIVE MAINTENANCE :

1. DE and NDE bearing.
2. Set of wear plates
3 V seal
4 Oil seal / Z pack
5 Paper Packing
6 R. V. spring
7. Coupling Spider
7.2 ADDITIONAL FOR 2 YEARS TROUBLE FREE SERVICE :
1. Rotor stator Assembly
2. Relief Valve Piston
8. CHECKING THE LEAKAGE FROM SUCTION LINE :
Leakage from the pump suction side can be checked as follows :
With the delivery line valve open, start the pump with the pump running, close the
suction valve as far as possible. As the suction valve is closed, stop the pump and
quickly close the delivery line valve. If the pump is properly pressure tight, the pressure
and vacuum gauge will show a constant vacuum. A reduction in the vacuum after the
delivery and suction valves are closed testifies the leakage in the suction cavities of the
pump beginning with the valve on the suction pipeline.
Page 157
9. TROUBLE SHOOTING CHART :
CAUSE REMEDIAL ACTION
9.1 PUMP NOT PRIMING THE LIQUID
A. Motor running in wrong Verify and change the connections.
direction
B. Pump is running dry A film is a must for effective priming hence
fillup the chamber with oil to allow film
formation.
C. Air leakage from suction Suction line should be 100 % tight. Check it
thoroughly in the way prescribed earlier.

D. Relief valve remain open Check the valve seat and ensure that
there is a perfect seat and spring is
adequately tight
E Discharge line is closed This does not allow displaced air to pass
away, hence keep the discharge line open.
Always use a non-return valve on
. discharge line.
9.2 NOISY OPERATION OF THE PUMP

A Air leakage from suction Slight air leakage can cause heavy port
noise like a jet plane.

B. NPSH available is less Always provide enough positive head at
suction. Provide NPSH more than the
required by as per manufacture’s demand.
Check the cavitation and change the pipe
to higher size & remove un necessary
joints and valve to improve upon NPSH.
9.3 PUMP SEIZED

A. Foreign particle in pumping Dismantle the pump Remove the media
foreign particle and smoothen the seized
area with the help of fine emery paper. If
necessary provide a suction strainer.

B Misalignment of the pump Check the alignment of pump with the
prime mover and get it corrected as
Page 158
mentioned earlier. If bearings (15) are
found damaged then replace it.
C Pump not used for long time Fil up the pump casing with kerosene and
rotate the pump with the help of catch till
the running is smooth. Now fill the pump
casing with lubrication oil and start.

D Pump operated in wrong Disassemble the pump Tighten the Counter
Sunk bolt. If the wearing plate is found
damaged replace it. Run the pump in the
direction marked by (->) label.
9.4 PUMP NOT DEVELOPING PRESSURE

A There may not be adequate PD pumps develop pressure by the
resistance in the discharge line resistance
overcoming in the pipe, hence
discharge line is of larger size than
specified, the pump may not resist with
sufficient pressure
B Due to excess internal Check the lateral end radial play of the
leakage rotor shaft, If any play is felt by
pushing/pulling the rotor shaft (06)
replace the wear plate (05) and bearings.

C Relief valve setting is not Check the relief valve set pressure and set
proper if by adjusting setting screw.
9.5 PUMP NOT DEVELOPING CAPACITY

A Starvation due to high suction Check the NPSH available at the
lift pump in let, this should be always more
than required by the pump.

B Starvation due to air leakage. Slightest air leakage from suction line
can reduce the inflow capability of the
pump. Hence check this and rectify.

C Pump not running at required Check the motor speed. If should be same
as specified on the pump name plate.

D Excess pressure on discharge Check the pressure on discharge line. It line
10
Page 159
should not be more than specified on
name plate.
E Internal leakage due to wear Check the play of the rotor shaft of the
and tear shaft (06) when pulled or pushed. If so
replace the wear plates. If there is radial
play. replace bearings / bushes (15) .
9.6 PULSATING OUTPUT

(SHARP OSCILLATION OF PRESSURE GAGE)
A Suction lift too high Decrease the suction lift.
B Leakage of air from the If the handled fluid viscosity is too high, suction line
cavitation may appear, which creates
pulsating output. warm up the liquid to
reduce its viscosity.
9.7 POWER CONSUMPTION TOO HIGH

A Delivery pressure too high Reduce the delivery pressure.
B Clearances between faces Increase the clearance between the pump
of rotor and inserts too small
housing and inserts by adding gaskets.
C Pump handles contaminated Disassemble the pump & gear its parts
fluid.with Pump working kerosene. If pump handless contaminated
surface & bearing get scared fluid. install a filter on the suction side.
& worn out
11
Page 160
12
Page 161
Page 162
Page 163
Page 164
Page 165
Page 166
Page 167
Page 168
Page 169
INSTALLATION, OPERATION AND MAINTENANCE OF
FABRICATED DUPLEX FILTERS
INSTALLATION
1. Ensure that the pressure rating of the filter is compatible with
the system.
2. Install filter after checking the direction of flow shown by
arrows on the filter and checking that sufficient clearance is
allowed to remove the filter element.
3. Remove transit plugs from filter.
4. Weld inlet and outlet pipe with mating flange.
5. Connect the mating flange with pipe, to inlet and outlet of filter.
OPERATION
1. Connect the handle (threaded pipe) to change over valve.
2. Set change-over lever in centre position to fill both filter casings
with oil.
Page 170
3. Open air vent valve . Close as soon as liquid escapes.
4. Set filter into working position by moving the change-over lever
to the left or right hand end position. Lever position always points
the non-operating filter.
CLEANING AND REPLACEMENT

OF FILTER ELEMENT
In case of clogging indicator – fitted, at pre-set differential
pressure, the red indicator becomes visible or the electrical
indicator is activated. Filter element of filter in operation is dirty
and cleaning or replacement is necessary.
1. Open the pressure equalization valve by moving the valve lever
to equalize the pressure in both the filters.
2. Put the stand-by filter in operation by changing the position of
change over valve.
3. Close equalization valve.
4. Open the air vent to reduce pressure in the filter housing. If
required open the drain valve and empty the filter.
5. Remove the filter cover of the filter housing. Remove the
compression spring and by pass valve (if fitted ).
6. Withdraw the filter element from the housing with a gentle
rocking movement.
7. Wash re-usable (S.S.) elements in a suitable solvent and blow
compressed air through the element from the inside to the outside.
Non-cleanable elements are discarded.
8. Clean the rod magnets if fitted.
9. Check the O-Rings of the element and renew defective O-rings.
Fit new or cleaned element on to the housing spigot. And re-fit
carefully compression springs and by pass valve.
Page 171
Data sheet
Pressure switch
RT
RT Pressure switches incorporate a pressure

controlled, single-pole change over swich where
the contact position depends on the pressure in
the connection port and the set value.
The RT series consists of pressure switches,
differential pressure switches and pressure
switches for neutral zone regulation, all for
general use within the industrial and marine
segments. The series also covers safety pressure
switches dedicated for steam boiler plants.
For installations in which operation is particularly
critical from safety and economic points of
view, the use of fail-safe pressure switches is
recommended.
The use of gold-plated contacts is also
recommended in such installations, provided
operation involves only a few switching cycles or
signal currents and voltages.
Features • Simple design • Long operation life time

• High accuracy • Available with all major marine approvals
• High repeatability
© Danfoss | DCS (jmn) | 2016.06 IC.PD.P10.B6.02 | 520B7310 |1

Page 172
Data sheet | Pressure switch, RT
Approvals
RT 30AW / RT 30AB / RT 30AS
RT 260A / RT 262A / RT 265A

RT 33B / RT 35W / RT 112W
/ RT 19W / RT 19B / RT 19S
RT 31W / RT 31B / RT 31S /
RT 116 / RT 117 / RT 200
/ RT 260AL / RT 262AL /
RT 1A / RT 5A / RT 121
RT 263AL / RT 266AL
RT 117L / RT 200L
RT 32W / RT 32B
Approvals
RT 1AL
RT 110
RT 112
RT 113
RT 1
RT 5
• • • • • • • • • • • • • CE marked acc. to EN 60947-4/-5
• • • VD Tüv, Germany
• • • • Det Norske Veritas, DNV
• • • • Lloyds Register of Shipping, LR
• • • • • • Germanischer Lloyd, GL
• • • • • Bureau Veritas, BV
• • • • • • • • • • • • • Registro Italiano Navale, RINA
• • • • • • • • • • • • • Russian Maritime Register of shipping, RMRS
• • • • • • • Nippon Kaiji Kyokai, NKK
• • • • • • • • • • • • • China Compulsory Certificate, CCC

Note: All RT are:
in addition we refer to the certificates,
the copies of which can be ordered yy CE marked in accordance with EN 60947-4/-5 for sale in Europe
from Danfoss
yy Further, the RT 19 , RT 30, RT 35, RT 112 W, RT 33, RT 31 and RT 32 series is CE markd in accordance
with PED 97/23/EC, category IV, safety equipment.
Overview/Survey
Range
0 5 10 15 20 25 30 [bar] Type
pe [bar]
-1 – 0 RT 121
0 – 0.3 RT 113
0.1 – 1.1 RT 112
0.2 – 3 RT 110
Standard pressure switches
-0.8 – 5 RT 1 / RT 1A
0.2 – 6 RT 200
1 – 10 RT 116
4 – 17 RT 5 / RT 5A
10 – 30 RT 117
-0.1 – 1.1 RT 112
Pressure switches for steam plant 0 – 2.5 RT 33B / RT 35W

approved by Vd TÜV 1 – 10 RT 30AW / RT 30AB / RT 30AS
2 – 10 RT 31W / RT 31B / RT 31S
5 – 25 RT 19W / RT 19B / RT 19S
5 – 25 RT 32W / RT 32B
-0.8 – 5 RT 1 AL
Pressure switches with adjustable 0.2 – 3 RT 110L

neutral zone 0.2 – 6 RT 200L
4 – 17 RT 5AL
10 – 30 RT 117L
Δp = 0.0 – 0.9 bar Differential pressure switches -1 – 6 RT 266AL
Δp = 0.1 – 1.0 bar -1 – 6 RT 263AL
Δp = 0.1 – 1.5 bar -1 – 9 RT 262AL / RT 262A
Δp = 0.5 – 4.0 bar -1 – 18 RT 260AL / RT 260A
Δp = 0.5 – 6.0 bar -1 – 36 RT 260A
Δp = 1.0 – 6.0 bar -1 – 36 RT 265A
2 | 520B7310 | IC.PD.P10.B6.02 © Danfoss | DCS (jmn) | 2016.06

Page 173
Technical data When ordering, please state type The type designation
and code nos. and code number. for the letters below means:
A: Unit suitable for the medium ammonia
L: Unit with neutral zone
Pressure switches
Code no.
Regulation
range Adjustable/ Max. Max.
(pe = fixed operating test Pressure Type
effective mechanical pressure pressure connection
pressure) differential PB p’ ISO 228/1
[bar] [bar] [bar] [bar]

-1 – 0 0.09 – 0.4 7 8 G 3/8 A 017-521566 RT 121
0 – 0.3 0.01 – 0.05 0.4 0.5 G 3/8 A 017-519666 RT 113
0.1 – 1.1 0.07 – 0.16 7 8 G 3/8 A 017-519166 017-519366 RT 112
RT 113 0.1 – 1.1 0.07 7 8 G 3/8 A 017-519266 RT 112
for manual setting; 0.2 – 3 0.08 – 0.25 7 8 G 3/8 A 017-529166 017-529266 RT 110
cover with windows 0.2 – 3 0.08 7 8 G 3/8 A 017-511066 RT 110
-0.8 – 5 0.5 – 1.6 22 25 7/16-20 UNF 017-524566 RT 1
-0.8 – 5 0.5 22 25 7/16-20 UNF 017-524666 RT 1
-0.8 – 5 0.5 – 1.6 22 25 G 3/8 A 1) 017-500166 RT 1A
-0.8 – 5 0.5 22 25 G 3/8 A 1) 017-500266 RT 1A
-0.8 – 5 1.3 – 2.4 22 25 G 3/8 A 1) 017-500766 RT 1A
0.2 – 6 0.25 – 1.2 22 25 G 3/8 A 017-523766 017-524066 RT 200
0.2 – 6 0.25 22 25 G 3/8 A 017-523866 017-523966 RT 200
1 – 10 0.3 – 1.3 22 25 G 3/8 A 017-520366 017-520066 RT 116
1 – 10 0.3 22 25 G 3/8 A 017-520466 017-519966 RT 116
4 – 17 1.2 – 4 22 28 G 3/8 A 017-525566 017-525366 RT 5
4 – 17 1.2 22 28 G 3/8 A 017-5094662) RT 5
4 – 17 1.2 – 4 22 28 G 3/8 A 1) 017-5046662) RT 5A
4 – 17 1.2 22 28 G 3/8 A 1) 017-5047662) RT 5A
10 – 30 1–4 42 47 G 3/8 A 1) 017-529566 017-529666 RT 117
RT 116 ) Supplied with ø6 / ø10 mm weld nipple. / 2) With seal cap
1
for tamper proof;

cap and blank cover Pressure switches with adjustable neutral zone
Regulation Max. Max. test
range Mechanical Adjustable operating pressure Pressure
pe differential neutral zone pressure, PB p’ Code no. Type
connection
[bar] [bar] [bar] [bar] [bar]
-0.8 – 5 0.2 0.2 – 0.9 22 25 G 3/8 A 1) 017L003366 RT 1AL
0.2 – 3 0.08 0.08 – 0.2 7 8 G 3/8 A 017L001566 RT 110L
0.2 – 6 0.25 0.25 – 0.7 22 25 G 3/8 A 017L003266 RT 200L
4 – 17 0.35 0.35 – 1.4 22 25 G 3/8 A 1) 017L004066 RT 5AL
10 – 30 1 1 – 3.0 42 47 G 3/8 A 017L004266 RT 117L
1
) Supplied with ø6 / ø10 mm weld nipple
Differential pressure switches

Adjustable Max. Max. test
Regulation Mechanical neutral Operation operating pressure Pressure
range (Δp) differential zone range pressure, PB p’ connection Code no. Type
ISO 228/1
[bar] [bar] [bar] [bar] [bar] [bar]
0 – 0.9 0.05 0.05 – 0.23 -1 – 6 7 8 G 3/8 A 1) 017D008166 RT 266AL
RT 262 A 0.1 – 1.0 0.05 0.05 – 0.23 -1 – 6 7 8 G 3/8 A 1) 017D004566 RT 263AL
Differential pressure switch 0.1 – 1.5 0.1 0.1 – 0.33 -1 – 9 11 13 G 3/8 A 1) 017D004366 RT 262AL
0.1 – 1.5 0.1 -1 – 9 11 13 G 3/8 A 1) 017D002566 RT 262A
0 – 0.3 0.035 -1 – 10 11 13 G 3/8 A 1) 017D0027662) RT 262A
0.5 – 4 0.3 0.3 – 0.9 -1 – 18 22 25 G 3/8 A 1) 017D004866 RT 260AL
0.5 – 4 0.3 -1 – 18 22 25 G 3/8 A 1) 017D002166 RT 260A
0.5 – 6 0.5 -1 – 36 42 47 G 3/8 A 1) 017D002366 RT 260A
1.5 –11 0.5 -1 – 31 42 47 G 3/8 A 1) 017D002466 RT 260A
Preferred versions 1–6 0.5 -1 – 36 42 47 G 3/8 A 1) 017D0072663) RT 265A
) Supplied with ø6 / ø10 mm nipple. / 2) Non-snap action contacts (see spare parts and accessories, contact system 017-018166)
1
) With SPST and SPDT contact system for alarm and cut off function at 0.8 and 1 bar
3
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Technical data The designation letters mean:

and ordering A: Units suitable for the medium ammonia. B: Safety units with external reset
W: Units for control purposes. S: Safety units with internal reset
Pressure switches for steam plant, PED approved acc. to EN 12953-9 and EN 12922-11
Code no.
Regulation
range Adjustable/ Max. Max.
Type
(pe = fixed operating test Pressure
effective mechanical pressure pressure connection
pressure) differential PB p’ ISO 228/1
[bar] [bar] [bar] [bar]
For rising pressure

0.1 – 1.1 0.07 7 8 G½A 017-528266 RT 112W
0 – 2.5 0.1 7 8 G½A 017-528066 RT 35W
1 – 10 0.8 22 25 G½A 017-518766 RT 30AW
1 – 10 0.4 22 25 G½A 017-518866 RT 30AB
1 – 10 0.4 22 25 G½A 017-518966 RT 30AS
5 – 25 1.2 42 47 G½A 017-518166 RT 19W
5 – 25 1 42 47 G½A 017-518266 RT 19B
5 – 25 1 42 47 G½A 017-518366 RT 19S
For falling pressure
0 – 2.5 0.1 7 8 G½A 017-526266 RT 33B
2 – 10 0.3 – 1 22 25 G½A 017-526766 RT 31W
2 – 10 0.3 22 25 G½A 017-526866 RT 31B
2 – 10 0.3 22 25 G½A 017-526966 RT 31S
5 – 25 0.8 – 3 42 47 G½A 017-524766 RT 32W
5 – 25 0.4 42 47 G½A 017-524866 RT 32B
Pressure switches for low pressure steam plant (pressure monitoring)- not PED approved
Preferred versions 0.1 – 1.1 0.07 – 0.16 7 7 G½A 017-518466 RT 112
Technical data Designation RT pressure switches

In general -50 – 70 °C ;
Ambient temperature Diaphragm version -10 – 70 °C
VD TÜV approved -40 – 70 °C
In general -40 – 100 °C;

Media temperature Diaphragm version -10 – 90 °C;
VD TÜV appr. -40 – 150 °C, see page 6 (Steam plant)
Single-pole changeover
Contact system switch (SPDT)
Alternating current:
AC-1: 10A, 400 V
Contact load
AC-3: 4A, 400 V
AC-15: 3A, 400 V
Direct current:
Contact material:
DC-13: 12 W, 230 V
AgCdO
(see fig. 6)
Fig. 6
Special contact system See “accessories” page 15
Cable entry 2 PG 13.5 for 6 – 14 mm diameter cables
IP66 acc. to IEC 529 and EN 60529. Units supplied with external reset.
Enclosure IP54. The thermostat housing is made of bakelite acc. to DIN 53470
Cover is made of polyamide.

Page 175
Materials in contact with the medium
RT 263AL / RT 266AL
RT 260A / RT 262AL
RT 200 / RT 200L
Material Part W .no. DIN
RT 260AL
RT 260A
RT 265A
RT 110
RT 112
RT 113
RT 116
RT 117
RT 121
RT 1A
RT 5A
RT 1
RT 5
Stainless steel 18/8 Bellows 1.4301 17440 x x x x x x x x x x x x x x x
Stainless steel 17/7 Spring 1.4568 17224 x x x x x
Brass Housing 2.0402 17660 x x x x x x x
Brass Bellows ring 2.0321 17660 x x x x x x x
Free-cutting steel Flare connection 1.0718 1651 x
Deep-drawn steel
Housing 1.0338 1623 x x x x x x x x
(nick.plated surface)
Weld connect.
Non-alli. carbon steel C 20 1.0402 1652 x x x x x x x
for connection
Aluminium Gasket 3.0255 1712 x x x x x x x x
Weld connection Bellows

Case hardening steel C 15 1.0401 1652
connect.
Stainless steel Spring guide + screw 1.4305 17440
NBR rubber Diaphragm x
Deep-drawn steel (surface

Diaphragm housing
DIN 50961 weld connection 1.0338 1623 x
with welded connector
Fe/Zn 5C)
Spring thread Spring 1.1250 17223 x
Materials in contact with the medium, PED approved switches

RT 30AW / RT 30AB
RT 19W / RT 19B /
RT 31W / RT 31B /
Material Part W .no. DIN RT 33B / RT 35W

/ RT 30AS
RT 112 W
RT 32WB
RT 19S
RT 31S
Stainless steel 18/8 Bellows 1.4301 17440 x x x x x x
Stainless steel 17/7 Orifice 1.4305 17440 x x
Steel C 15 Connector 1.0401 1652 x x
Deep-drawn steel + Ni Bellows ring 1.0338 1623 x x x x x x
Stainless steel 17/7 Bellows spring 1.4568 17224 x x
Stainless steel Ring 1.4305 17440 x
Deep-drawn steel + Ni Housing 1.0338 1623 x x x x x x
Stainless steel Bellows connect. 1.4305 17440 x
Stainless, weldable
Connector 1.4301 17440 x x x x
freecutting steel
Deep-drawn steel + Sn Spring guide 1.0338 1623 x
Brass Housing 2.0402 17660
Brass Bellows ring 2.0321 17660
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520B7310
176| 5
Application Control and monitoring of pressure differentials elements and the set scale value. This unit is also
A differential pressure switch is a pressure available with an adjustable neutral zone (like the
controlled switch that cuts in and cuts out the RT-L which is described on page 9.
current dependent on the pressure differential
between the counteracting bellows
Setting The setting disc (5) becomes accessible when the

front cover is removed. The differential pressure
is set by turning the disc with a screwdriver while
reading the scale (9).
For differential pressure switches with a

changeover contact system, the contact
differential is given as the differential pressure
switches have a fixed differential. In units with
an adjustable neutral zone, the neutral zone disc
must also be set. See diagram in fig. 16.
Note:
5. Setting disc When installing, the low pressure connection (LP)
Fig. 15
9. Range scale must always be upwards
NZ = NATURALZONE / DEADZONE NZ = NATURALZONE / DEADZONE NZ = NATURALZONE / DEADZONE NZ = NATURALZONE / DEADZONE
DIFF RANGE DIFF RANGE DIFF RANGE

DIFF RANGE
POSITION POSITION POSITION
POSITION
Fig. 16
© Danfoss | DCS (jmn) | 2016.06 IC.PD.P10.B6.02 | 520B7310

Page 177 | 11
Function
Scale setting −−−−
Mechanical differential
Fig. 17
Contact function, setting
of falling differential pressure
a. Units with changeover switch (SPDT) I. Contacts make when differential pressure
If the differential pressure falls below the set falls below the range scale setting.
value, contacts 1-е2 make and contacts 1-4 II. Contacts make when pressure rises above
break. Contacts 1-2 break again and contacts 1-4 the range scale setting plus the fixed
make when the differential pressure has risen mechanical differential.
to the set range value plus the fixed contact
differential.
Range setting
Inlet pressure
Differential (mechanical
differential) corresponds
to the least neutral
zone setting.
The neutral zone and inlet

differential pressure may
vary within this interval
without resulting in
a make function 1-2 or 1-4.
Fig. 18. Contact function, setting of neutral zone
b. Units with adjustable neutral zone (SPDTNP) The contact function can be summed
If the differential pressure rises above the set up as follows:
value plus the differential, contacts 1-4 make. I. Setting disc set for falling differential pressure.
If the pressure falls by the amount of the II. Neutral zone disc set for rising differential
differential (which is fixed in this unit), contacts pressure.
1-4 break. If the pressure falls to the neutral zone
minus the differential, contacts 1-2 make. When
the differential pressure rises again by an amount
corresponding to the differential, contacts 1-2
break again.
Example 1 Example 2
When the differential pressure exceeds 1.3 bar, a The speed of a circulation pump must be
filter needs cleaning. The static pressure over the controlled to give a constant differential pressure
filter is 10 bar. of 10 m wg in a heating plant. The static plant
According to the ordering table on page 4, the pressure is 4 bar. The choice is an RT 262AL.
choice is an RT 260A (the RT 262A has a max. The differential disc (5) fig. 15 page 13, must be
operating pressure on the low pressure side set at 1 bar (10 m wg) minus the fixed differential
(LP) of 6 bar and is therefore not suitable for this of 0.1 bar, i.e. 0.9 bar. The neutral zone disc is
application). factory-set (marked in red).
Setting: Since a signal is required for rising
differential pressure, the setting becomes
1.3 - 0.3 bar = 1.0 bar.

Page 178
Dimensions [mm] and

weights [kg] RT 5, RT 110, RT 112, RT 116, RT 117, RT 200
Special version with tamper proof

cap and blank cover
RT 5, RT 110, RT 112,
RT 13 RT 116, RT 117 / RT 117L, RT 5 RT 1A / RT 1AL
RT 121, RT 200 / RT 200L
RT 262A / RT 262A /
RT 260A / RT 260AL RT 5 RT 5A / RT 5AL
RT 263AL
17-660-15
17-660-15
17-660-15
: External reset
Danfoss
Danfoss
Danfoss
knob only for RT...B
RT 30AW / RT 30B / RT 30S L = 225

RT 19W / RT 19B / RT 19S L = 228
RT 33B / RT 35W L = 221
RT 112W L = 210
RT 31W / RT 31B / RT 31S L = 212
Weight: approx. 1 kg RT 32W / RT 32B L = 212
© Danfoss | DCS (jmn) | 2016.06 IC.PD.P10.B6.02 | 520B7310

Page 179 | 13
Plate Heat Exchanger
Operational and Maintenance Manual
Page 180
NOTICE
TO AVOID HAND INJURIES,

PROTECTIVE GLOVES
SHOULD ALWAYS BE WORN
WHEN HANDLING PLATES.
PROTECTIVE SHROUDS
IT IS THE RESPONSIBILITY OF EACH PERSON OPERATING OR

REPAIRING EQUIPMENT TO TAKE THE NECESSARY PRECAUTIONS
TO COMPLY WITH ALL APPLICABLE SAFETY REGULATIONS.
ALFA LAVAL PROVIDES PROTECTIVE SHROUDS FOR ALL OUR

PLATE HEAT EXCHANGERS. THESE SHROUDS WILL PREVENT
POSSIBLE INJURIES AND/OR DAMAGE AS A RESULT OF SUDDEN
LEAKAGE FROM THE PLATE PACKAGE.
Page 181
List of contents
CHAPTER
TO OUR VALUED CUSTOMER 1

• Alfa Laval Locations 1.1
THE NAME PLATE - AND THE 2

IDENTIFICATION OF THE EQUIPMENT
• Code Plate & Identification Number Locations 2.1, 2.2
GENERAL 3
• Storage 3.1, 3.2
• Lifting 3.3
• Foundation 3.4
• Installation 3.5
• Special Loose Flange Connections 3.6
THE MAIN COMPONENTS AND THEIR FUNCTIONS 4A

FOR PARALLEL FLOW UNITS
• List of Parallel Flow Units 4A.1
• Function 4A.2
• How It Works 4A.3
• Heat Transfer 4A.4
• Pressure Drop 4A.4
• Plates 4A.5
• Gaskets 4A.6, 4A.7, 4A.8
THE MAIN COMPONENTS AND THEIR FUNCTIONS 4B

FOR DIAGONAL FLOW UNITS
• List of Diagonal Flow Units 4B.1
• Function 4B.2
• How It Works 4B.3
• Heat Transfer 4B.4
• Pressure Drop 4B.4
• Plates 4B.5, 4B.6
• Gaskets 4B7, 4B.8, 4B.9, 4B.10
Page 182
List of contents
CHAPTER
OPERATION 5
• Starting Up 5.1, 5.2
• Unit in Operation 5.3
• Shut Down 5.3
• The Risks of Not Complying With 5.4
The Start-Up and Shut-Down Procedures
OPENING AND CLOSING OF THE PLATE PACKAGE 6

• Opening 6.1, 6.2, 6.3, 6.4, 6.5
• Removal and Insertion of plates 6.6
• Closing 6.7, 6.8, 6.9, 6.10, 6.11
MAINTENANCE 7
• Cleaning 7.1, 7.2, 7.3, 7.4, 7.5
• Regasketing 7.6, 7.7, 7.8, 7.9
• End Plate II Gaskets For Parallel Flow Units 7.10
• End Plate II Gaskets For Diagonal Flow Units 7.11
FAULT DETECTION 8
• Leakage at Connections or Plates 8.1, 8.2
• Internal Mixing of Media 8.3
• Pressure Drop Problems 8.4
• Heat Transfer Problems 8.5
SUPPLEMENTARY PARTS 9
• Partition Plate 9.1
• Instrument Ring 9.2
Page 183
1
To our valued customer:
Thank you for purchasing an Alfa Laval Plate Heat Exchanger. As the world's largest
manufacturer of Heat Exchangers, we are very proud of our products and services. We value you
as our customer and wish to assure your satisfaction. We have prepared this Instruction Manual
to assist you with your Alfa Laval Plate Heat Exchanger in various situations. We suggest that
you look through it carefully, and, above all, make it readily available to any personnel who may
need it for reference.
1.1
Page 184
2 The name plate
- and the identification of the equipment
Model type and

manufacturing numbers(s)
A name plate like the one shown below is fixed to the apparatus as shown above and
it gives the following information
2.1
Page 185
The name plate 2
- and the identification of the equipment
This instruction manual has been issued for many different

models of Alfa Laval industrial PHEs. There are separate
manuals for industrial, sanitary, spiral, alfa rex, brazed &
evaporator/condensor heat exchangers.
• WHENEVER USING THE MANUAL, CHECK FIRST THAT THE

SERIAL NUMBER ON THE FRONT COVER IS IDENTICAL TO
THAT ON THE NAME PLATE OF THE EQUIPMENT.
• IN ALL CORRESPONDENCE WITH ALFA LAVAL, PLEASE

REFER TO THE MANUFACTURING SERIAL NUMBER, FOR
TRUE IDENTIFICATION OF THE EQUIPMENT.
• WHENEVER CONTACTING ALFA LAVAL ABOUT A PART FOR

YOUR PLATE HEAT EXCHANGER, BE SURE TO STATE THE
MANUFACTURING SERIAL NO.(S), AND MODEL TYPE.
2.2
Page 186
3 General
STORAGE
In this section, names of heat exchanger parts are mentioned for

the first time. For your information, see Chapters 4A or 4B
FUNCTION.
A 1. Unless otherwise agreed, ALFA LAVAL delivers

the plate heat exchanger ready to be put in
service upon arrival. This means that the
plate package is tightened to its correct
measurement A.
Should it be necessary, however, to store the equipment for a

longer period (1 month or more) before, certain precautions should
be made in order to prevent unnecessary wear of the equipment:
2. Preferably, the heat exchanger should be

stored inside, in a room with a temperature
around 15 to 20 degrees Celsius (60 to 70
degrees Fahrenheit) and humidity around 70%
There should ABSOLUTELY NOT be any

OZONE-PRODUCING equipment in the room,
like electric motors or arc-welding equipment,
since ozone destroys many rubber materials
(cracking).
Do not store organic solvents or acids in the

room.
Avoid heat or ultraviolet radiation.
3. Wrapping the PHE with a non-transparent

plastic film is a good precaution. Use of
transparent film can alter paint color if unit is
stored in direct sunlight.
3.1
Page 187
General 3
STORAGE
4. The tightening bolts should be well covered
with good rust preventing coating, suitable
types (LUBRIPLATE FGL-2 or Equivalent) and
if not connected to the pipe system, the con-
nections should be covered.
If the heat exchanger must be stored outdoors,

the precautions mentioned above should be
taken as far as practical. The need for protec-
tion against the climate etc. is of course even
more important in this case.
5. If for any reason the heat exchanger is

removed from service for a long period, it is
advantageous to follow the advice above, even
if the equipment is not moved from the location.
The heat exchanger should be VENTED AND

DRAINED, and depending on the media
processed, it is recommended to RINSE AND
DRY it, before it is stored.
LIFTING
1. Whenever the heat exchanger is lifted, straps
should be placed around tightening bolts
on both sides of the unit, as shown in picture. If
lifting lugs or lifting eyes are provided, always
use chains or lifting cables rated above the
published weight of the heat exchanger.
NEVER LIFT BY THE CONNECTIONS OR THE STUDS AROUND THEM!

3.2
Page 188
3 General
LIFTING CONTINUED
If Lifting Lugs are provided
If you are to lift the heat exchanger itself, straps WARNING!

should be used. They should be placed as Never lift by the connections or the studs
shown on the picture. around them.
On smaller units (4” connected size smaller)

typically two lifting lugs are required instead
of four.
3.3
Page 189
General
FOUNDATIONS.
3
All information necessary for the preparation of the foundation
appears on the data sheet provided by ALFA LAVAL.
In some cases (installation on board a ship,

when processing corrosive liquids, etc.) it may
be practical to place the heat exchanger in a
DRAINAGE BOX (with capacity for the total
volume of the heat exchanger). The outlet of
the drainage box should be generously
2” (50mm) dimensioned, not less than (2”) 50 mm
4”
(100mm)
diameter.
INSTALLATION.
BEFORE connecting any piping to the heat exchanger, MAKE SURE THAT ALL
FOREIGN OBJECTS HAVE BEEN FLUSHED OUT OF THE SYSTEM!
Wx1.5 Wx1.5 Wx1.5
PLEASE OBSERVE THAT PLEASE OBSERVE THAT

The measurements given in the picture above The measurements given in the picture are
are recommended by ALFA LAVAL, it is recommended by ALFA LAVAL, to provide
necessary to leave free space around the reasonably good working conditions during
equipment, to provide access and make future installation of the heat exchanger as well as
service possible. Except for a place to put the for future maintenance and service. If floor
plates, if removed from the heat exchanger, space is restricted, the dimensions suggested
NO FURTHER SPACE is required for can be reduced. It is left to the purchaser
servicing the PHE. to decide just how much access space
is required.
This field should be kept free Recommended free space for

from fixed installations. opening and closing.
3.4
Page 190
3 General
PIPES
Always ensure that no measurable stress is

placed on the heat exchanger by the piping
system.
SHUT OFF VALVES
To enable the heat exchanger to be opened

when necessary shut off valves should be pro-
vided on all connections.
PRESSURE RELIEF DEVICES
It is the responsibility of the user to ensure

that the required pressure relief devices are
properly installed prior to initial operation. Refer
to the applicable Code(s) and corresponding
Standard(s) for proper size requirements of
these pressure relief devices.
CONNECTIONS ON THE PRESSURE PLATE

(REAR COVER)
Some plate heat exchangers may also have

connections on the pressure plate. In such
cases, it is important to check against the
drawing or the name plate that the plate pack
has been tightened to the right measurement
before the piping is connected.
Whenever piping is connected to the pressure

plate, a short 90o spool piece shall be installed
between the heat exchanger and the piping.
These should be directed upwards or side-
ways. This simplifies pressure plate removal
during servicing.
Venting of both sides of the heat exchanger

must be provided. This is important
and enables air to be drawn from the system
during start-up. It also enables air or gas to
be removed during operation, and it enables
faster drainage.
3.5
Page 191
General 3
Special Loose Flange Connections
Loose Flanges are provided on certain model

types due to interference. When provided these
flanges shall be incorporated into the piping.
MODELS WITH BOTH "S" AND "T" PORT

CONNECTIONS
M6-FD, M6-MFD, M6-MWFD, M10-BFD,

M10-MFD, M10-BWFD, M10-BDFD, M20-MFD*,
M20-MWFD*
MODEL TYPES WITH LOOSE FLANGE ON

T PORT CONNECTIONS ONLY:
M6-FG, M6-MFG, M6-MWFG, M10-BFG,

M10-MFG, M10-BWFG, M10-BDFG, V28-FD*,
V45-FD*, M20-MFG, M20-MWFG
* Loose flange only when design pressures

above 230 psi.
Notes:
1) Sports connections on these model types
utilized industry standard flanges.
2) Not all exchangers require T port connections.
PIPING CONNECTION
The loose flange is connected to piping by use

of a commercially available stub end of same
material as the piping.
The stub end is installed as shown and then butt

weld to the piping.
3.6
Page 192
4A LIST OF PARALLEL FLOW UNITS
“A” SERIES UNITS:

AM10-FG; AM10-FS
A15-BFL; A15-BFG; A15-BFD; A15-BWFG; A15-BWFD
A20-BFL; A20-BFG; A20-BFD
AM20-FG; AM20-BFG; AM20-WFG; AM20-SFG; AM20-DWFG
AK20-FG; AK20-FD; T200-FG; T200-FD
AX30-BFG; AX30-BFD; AX30-BWFG; AX30-BWFD
A35-HA
“M” SERIES UNITS:

M3-VG
M6-FG; M6-FD; M6-MFG; M6-MFD; M6-MWFD/FG/FDR/FGR
M10-BFM; M10-BFG; M10-BFD; M10-MFG; M10-MFD;
M10-BWFG; M10-BWFD; M10-BWFGR, M10-BWFDR
M15-BFG; M15-BFD; M15-BFS; M15-MFG;
M15-MFD; M15-MFS; MK15-BWFD; MK15-BWFG
M20-MFG; M20-MFM; M20-MFD; M20-MWFG; M20-MWFD
M30-FM; M30-FG; M30-FD
MA30-FD; MA30-FG; MA30-WFG; MA30-WFD
MX25-BFG; MX25-BFD; MX25-BFS
EC500-WTFE; EC500-WTFL
“V” SERIES UNITS:

V8-VG, V13-FG, V13-FD, V20-FG, V20-FD
4A.1
Page 193
PARALLEL FLOW UNITS 4A
Function
THE MAIN COMPONENTS OF THE PLATE HEAT EXCHANGER AND THEIR FUNCTIONS.
In ALFA LAVAL Plate Heat Exchangers, heat is transferred from one medium to another through
thin metal plates which have been pressed into a special pattern.
3. CONNECTIONS
Holes matching the piping lead
through the frame plate, permitting
1. FRAME PLATE the media to enter into the heat
exchanger. Threaded studs around
2. SUPPORT COLUMN the holes secure the pipes to the
The two bars are suspended equipment. Depending on the
between the FRAME PLATE, to application, metallic or rubber-type
which in most cases the piping is 2. 1. 3.
LININGS may protect the edges of
connected, and a SUPPORT the holes against corrosion.
COLUMN.
4.
6. TIGHTENING BOLTS
With the package of thin plates
hanging between the frame plate
4. CARRYING BAR and the pressure plate, a number
of TIGHTENING BOLTS are used
5. GUIDING BAR 6. to press the thin plates together,
The plates hang from a CARRYING bringing them into metallic contact,
BAR at the top and are kept in line by and to compress the gaskets,
a GUIDING BAR at the bottom. enough to seal off the narrow
passages which have now been
5. formed between the plates.
7. 8. 8. CHANNEL PLATES
9. GASKET
7. PRESSURE PLATE These plates are called CHANNEL
The pressure plate is hung on the PLATES. A groove along the rim
carrying bar and is moveable, as are of the plate and around the ports
the heat transfer plates. In some hold a GASKET, usually made of a
cases piping may be connected to rubber-type material.
the pressure plate.
Heat is transferred through the
surface which is contained by the
gasket, except for some small areas
9. near the corners.
The number of plates in your heat

exchanger is determined by the size
of the heat transfer surface required.
4A.2
Page 194
4A PARALLEL FLOW UNITS
How it works
S1
S4
A B
5
B A
4
A
3
B
2
S2
A
1 S3
B
B
A
When a package of plates are pressed together, During the passage through the equipment,
the holes at the corners form continuous tunnels or the warmer medium will give some of its heat
manifolds, leading the media (which energy to the thin wall, which instantly loses it
participate in the heat transfer process) from the again to the colder medium on the other side.
inlets into the plate pack, where they are
distributed in the narrow passages between the The warmer medium drops in temperature,
plates. while the colder one is heated up.
Because of the gasket arrangement on the plates, Finally, the media are led into similar hole-
and the placing of “A” and “B” plates alternately, the tunnels at the other end of the plates and
two liquids enter alternate passages, e.g. the warm discharged from the heat exchanger.
liquid between even number passages, and cold
liquid between odd number passages.
Thus the media are separated by a thin metal wall.

In most cases the liquids flow in opposite
directions.
4A.3
Page 195
Heat transfer
The purpose of the equipment is to transfer heat

from one medium to another. Heat passes very
easily through the thin wall separating the two
media.
The novel pattern into which the plate material

has been formed not only gives strength and
rigidity, but greatly increases the rate of heat
transfer from the warmer medium to the metal wall
and from the wall to the other medium.
This high heat flow through the walls can be

seriously reduced by the formation of deposits of
various kinds on the wall surfaces.
The pattern of corrugation on Alfa Laval plates

mentioned above induces highly turbulent flow.
The turbulence gives strong resistance to the
formation of deposits on the plate surface; howev-
er, it cannot always eliminate fouling.
The deposits may increase the total “wall

thickness” substantially, and they consist of
materials that have a much lower thermal
conductivity than the metal plate. Consequently a
layer of deposits can severely reduce the overall
heat transfer rate.
The deposits will be considered in the chapter on

MAINTENANCE and CLEANING. At this point
we will only establish that this fouling is unwanted
and can under certain circumstances, be harmful
to the heat exchanger because corrosion may
occur under the deposits.
Pressure drop
Pressure drops are wasted energy. It is clear that the fouling of the surfaces is
undesirable.
All pipe systems and equipment included in
them offer resistance to media flowing through Larger particles and fibers may also be drawn
them. into the heat exchanger and clog the passage
ways if strainers or other means of protection
Some pressure drop is unavoidable, but for a have not been provided for.
given PHE it should be kept as close as
possible to the designed value. A reduced ability by the heat exchanger to hold
the desired temperatures, in combination with
The formation of deposits on the heat transfer an increased pressure drop on any of the
surfaces instantly leads to a reduction of the media, indicates that fouling or clogging is
free space between the plates. This means that taking place.
more energy is needed to get the desired flow
through the equipment. For corrective action, see MAINTENANCE and
CLEANING.
4A.4
Page 196
Studying the pictures, you will observe that on a plate hanging

vertically, the gasket rests in a groove which includes the heat
transfer area
and two corners on the OR two corners on the

left side. right side.
Smaller rings surround the

two remaining corners.
We decide that we will name the plates

after these two situations.
An A-plate is a A B-plate is a
plate hanging with plate hanging with
the chevron pointing the chevron pointing
downwards. upwards.
A B
If we turn an A-plate upside down we will have a B-plate:

4A.5
Page 197
Gaskets
The GASKET is molded in one piece. The material is normally an
elastomer, selected to suit the actual combination of temperature,
chemical environment and possible other conditions that may be
present.
The one-piece gasket consists of:

1. One field gasket
2. Two ring gaskets
3. Links
The field gasket is by far the larger part

containing the whole heat transfer area and
1 the two corners connected to it. The ring
gaskets seal off the remaining two corners.
These three pieces are held together by a

few short links, which have no sealing
function at all. Their purpose is simply to tie
the pieces together and to add some
support in certain areas. On some plate
heat exchangers, the gasket is held in place
on the plate by means of a suitable cement
or glue.
4A.6
Page 198
Gaskets
As already demonstrated, the two media are
effectively kept apart by the ring and field gas-
kets. To prevent intermixing of the media in the
corner areas where field and ring gaskets are
very close to each other, the link pieces have a
number of slots which opens the area between
the field and ring gaskets to atmosphere. Any
leakage of media across either gasket will
escape from the heat exchanger through the
slots.
It is important that these openings are kept

clear. If they are not, there is a risk that should a
leak occur in that region of the plate, there might
be a local pressure build-up, which could allow
one medium to mix with the other.
Care should be taken not to cut or scratch the

gaskets while handling plates.
4A.7
Page 199
TRANSITION PLATE
M30, MX25, A20-B, AM20, AK20, T200, A15-B, M15, M10, M6
Ring Gaskets
Collars (Metal)
Channel Plate Gaskets
Pressure Plate
4A.8
Page 200
4B List of Diagonal Flow Units
“A” SERIES UNITS:

A10-BFG; A10-BFD
AX35-FG
A45-FG
“P” SERIES UNITS:

P2-FG; P2-VLCH; P2-DWFG
P3-E;P3-EH
“M” SERIES UNITS:

M3-XVG
“V” SERIES UNITS:

V28-FG, V28-FD, V45-FG, V45-FD, V110-FG, V110-FD,
V170-FG, V170-FD, V280-FG, V280-FD
4B.1
Page 201
DIAGONAL FLOW UNITS 4B
Function
THE MAIN COMPONENTS OF THE PLATE HEAT EXCHANGER AND THEIR FUNCTIONS.
In ALFA LAVAL Plate Heat Exchangers, heat is transferred from one medium to another through thin
metal plates which have been pressed into a special pattern.
3. CONNECTIONS
Holes matching the piping lead
1. FRAME PLATE through the frame plate, permitting
the media to enter into the heat
2. SUPPORT COLUMN exchanger. Threaded studs around
The two bars are suspended the holes secure the pipes to the
between the FRAME PLATE, equipment. Depending on the
to which in most cases the piping 2. 1. 3. application, metallic or rubber-type
is connected, and a SUPPORT LININGS may protect the edges of
COLUMN. the holes against corrosion.
4.
6. TIGHTENING BOLTS
With the package of thin plates
hanging between the frame plate and
4. CARRYING BAR the pressure plate, a number of
TIGHTENING BOLTS are used to
5. GUIDING BAR 6. press the thin plates together bringing
The plates hang from a CARRYING them into metallic contact, and to
BAR at the top and are kept in line by compress the gaskets enough to seal
a GUIDING BAR at the bottom. off the narrow passages which have
5. now been formed between the plates.
8. CHANNEL PLATES
7. 8.
9. GASKET
These plates are called CHANNEL
7. PRESSURE PLATE PLATES. A groove along the rim of
The pressure plate is hung on the the plate and around the ports hold a
carrying bar and is moveable, as are GASKET, usually made of a rubber-
the heat transfer plates. In some type material.
cases piping may be connected to
the pressure plate. Heat is transferred through the
surface which is contained by the
gasket, except for some small areas
near the corners.
9.
The number of plates in your heat
exchanger is determined by the size
of the heat transfer surface required.
4B.2
Page 202
4B DIAGONAL FLOW UNITS
How it works
S1
S4
A 5 B
B A
4
A
3
B
2
A S2
1 S3
B
A
B
When a package of plates are pressed together, During the passage through the PHE,
the holes at the corners form continuous tunnels the warmer medium will give some of its heat
or manifolds, leading the media (which participate energy to the thin wall, which instantly loses it
in the heat transfer process) from the inlets into again to the colder medium on the other side.
the plate pack, where they are distributed in the
narrow passages between the plates. The warmer medium drops in temperature,
while the colder one is heated up.
Because of the gasket arrangement on the
plates, and the placing of “A” and “B” plates Finally, the media are led into similar hole-
alternately, the two liquids enter alternate tunnels at the other end of the plates and
passages, e.g. the warm liquid between even discharged from the heat exchanger.
number passages, and cold liquid between odd
number passages.
Thus the media are separated by a thin metal

wall. In most cases the liquids flow in opposite
directions.
4B.3
Page 203
Heat transfer
The purpose of the equipment is to transfer heat

from one medium to another, and heat passes
very easily through the thin wall separating the
two media.
The novel pattern into which the plate material

has been formed not only gives strength and
rigidity, but greatly increases the rate of heat
transfer from the warmer medium to the metal wall
and from the wall to the other medium.
This high heat flow through the walls can be

seriously reduced by the formation of deposits of
various kinds on the wall surfaces.
The pattern of corrugation on Alfa Laval plates

mentioned above induces highly turbulent flow.
The turbulence gives strong resistance to the
formation of deposits on the plate surface; howev-
er, it cannot always eliminate fouling.
The deposits may increase the total “wall

thickness” substantially, and they consist of
materials that have a much lower thermal
conductivity than the metal plate. Consequently a
layer of deposits can severely reduce the overall
heat transfer rate.
The deposits will be considered in the chapter on

MAINTENANCE and CLEANING. At this point
we will only establish that this fouling is unwanted
and can under certain circumstances, be harmful
to the heat exchanger because corrosion may
occur under the deposits.
Pressure drop
Pressure drops are wasted energy. It is clear that the fouling of the surfaces is
undesirable.
All pipe systems and equipment included in them
offer resistance to media flowing through them. Larger particles and fibers may also be drawn
into the heat exchanger and clog the passage
Some pressure drop is unavoidable, but for a ways if strainers or other means of protection
given PHE it should be kept as close as have not been provided for.
possible to the designed value.
A reduced ability by the heat exchanger to hold
The formation of deposits on the heat transfer the desired temperatures, in combination with an
surfaces instantly leads to a reduction of the increased pressure drop on any of the media,
free space between the plates. This means indicates that fouling or clogging is taking place.
that more energy is needed to get the desired
flow through the equipment. For corrective action, see MAINTENANCE and
CLEANING.
4B.4
Page 204
Plates
Studying the pictures, you will observe that on a plate hanging

vertically, the gasket rests in a groove which includes the heat
transfer area
rings surround
the remaining corners
and two corners (the OR two corners (the upper

upper left-hand corner right-hand corner and
and the lower right- the lower left-hand
hand corner. corner.
rings surround the

two remaining corners
Depending on which two corners are included with the heat

transfer area, the plate is called an A- or a B-Plate.
An A-plate is a A B-plate is a
plate hanging with plate hanging with
the chevron pointing the chevron pointing
downwards. A B upwards.
4B.5
Page 205
Plates
We can make a B-Plate from an A-plate or the opposite,
by changing the gasket and turning the plate upside down.
1. 2. 3.
4. 5.
4B.7
Page 206
Gaskets
The GASKET is molded in one piece. The material is normally
an elastomer, selected to suit the actual combination of
temperature, chemical environment and possible other
conditions that may be present.
3
The one-piece gasket consists of:
1. One field gasket
2. Two ring gaskets
3. Links
The field gasket is by far the larger part

containing the whole heat transfer area and the
two corners connected to it. The ring gaskets seal
off the remaining two corners.
1 These three pieces are held together by a few

short links, which have no sealing function at all.
Their purpose is simply to tie the pieces together
and to add some support in certain areas. On
some plate heat exchangers, the gasket is held in
place on the plate by means of a suitable cement
or glue.
4B.8
Page 207
Gaskets
As already demonstrated, the two media are

effectively kept apart by the ring and field
gaskets. To prevent intermixing of the media in
the corner areas where field and ring gaskets are
very close to each other, the link pieces have a
number of slots which open the area between the
field and ring gaskets to atmosphere. Any
leakage of media across either gasket will
escape from the heat exchanger through these
slots.
It is important that these openings are kept

clear. If they are not, there is a risk that should
a leak occur in that region of the plate, there
might be a local pressure build-up, which could
allow one medium to mix with the other.
Care should be taken not to cut or scratch the

gaskets while handling plates.
4B.9
Page 208
TRANSITION PLATE
M30, MX25, A20-B, AM20, AK20, T200, A15-B, M15, M10, M6
Ring gaskets
Collars (Metal)
Channel plate gaskets
Pressure plate
4B.10
Page 209
NON MACHINED PRESSURE PLATE
Sheet Lining
Pressed Collar
Ring Gasket
End Plate
Transition Plate
MACHINED PRESSURE PLATE (AX30, AM20 AND OBSOLETE FRAMES)
Rubber Gasket
Weld
Sheet Lining, same

material in metal ring
Metal Ring
4B.11
Page 210
5 Operation
1. START UP
1. BEFORE STARTING UP FOR THE FIRST
TIME OR AFTER A LONG TIME IN
STORAGE: MAKE SURE THAT THE
PLATE PACK IS COMPRESSED TO THE
CORRECT MEASUREMENT A! Check
with the Drawing or Nameplate, which is
provided with each heat exchanger.
It is very important that the system to which

the heat exchanger is connected, is
2. protected against sudden and extreme
variations of temperature and pressure.
This is not only for the heat exchanger but
also for the pipe system itself and every
piece of equipment included in it.
This should be kept in mind whenever a

maneuver is to be carried out, including
starting up of the pumps in the system.
3.
2. Before starting any pump, check whether
instructions exist, telling you which pump
should be started first.
3. Check that the valve between the pump

and the equipment, controlling the flow rate
of the system which you are about to start
up is closed.
4.
4. Check that the valve at the exit, if there is

one, is fully open.
5.1
Page 211
Operation 5
5.
5. Open the vent.
6.
6. Start the Pump.
7.
7. Open the valve slowly.
8.
8. When all air is out, close the vent.
9. Repeat the procedure for the other media.
5.2
Page 212
5 Operation
UNIT IN OPERATION
Any adjustment of the flowrates required to As long as the PHE is operating to satisfaction,
maintain correct temperatures or pressure it should be left without any interference.
drops should be made slowly, in order to
prevent shocks to the system.
Problems in keeping up the performance of

the heat exchanger may be caused by a
change in some of the temperature
conditions, the heat load or by fouling.
SHUT-DOWN
If the heat exchanger is going to be shut down - or if for any reason
the pumps are to be stopped - the following procedure should be
followed:
1. 1. First establish whether instructions

exist that specify which side
should be stopped first.
2. SLOWLY CLOSE THE VALVE

controlling the flow rate of the
pump you are about to stop.
2.
3. When the valve is closed, stop the

pump.
4. Repeat the procedure for the other

side.
5. Poor quality cooling water may be

hazardous to metallic materials.
3. Typical examples are corrosion of
stainless steels and nickel alloys.
If for any reason the heat

exchanger is shut down for a
longer period (more than a
number of days), it should be
drained, and depending on the
media processed, it is
recommendable to rinse and dry it.
5.3
Page 213
Operation 5
THE RISKS OF NOT COMPLYING WITH THE START-UP
AND SHUT-DOWN PROCEDURES.
A liquid in motion in a pipe system represents
a lot of energy, and it must be very carefully dealt Valves must be operated gradually. The longer
with. the pipes and the higher the flow rate, the more
important this becomes.
Particularly when the fluid is stopped it is imper-
ative that this is done smoothly.
NOTE!
For this reason fast-closing valves should not be
used unless the pipes of the system are very
short.
WATER HAMMER is the name given to a short In the worst case, the pressure surge caused by
duration pressure peak, traveling along the pipe such a sudden stop of the motion of a fluid, can
as a wave at the speed of sound, and resulting be several times the normal pressure of the
from a sudden deceleration of the motion of the system.
fluid in a closed system.
Therefore it is very important for the protection
Thus, it is usually related to the shutting down of of the whole installation that start-ups and close-
a system. However, when starting up a system downs are carried out with great care.
with open valves and empty pipes, the fluid may
burst into some obstacle, like a fine mesh strain-
er, a flow meter or a heat exchanger, causing a
sudden reduction of the flow velocity - if not a
complete halt, and so we may have the conditions
of a Water Hammer.
5.4
Page 214
6 Opening
1. 4.
(100oF)
1. Slowly close the valves on the 4. If the heat exchanger is hot, wait
inlets. Shut off the inlet side, until it has cooled down to about
closing the highest pressure first. 40oC (100oF).
2. 5.
2. Switch off pumps.
5. Drain
3. 6.
3. Close the valves on both outlets. 6. Dismantle any pipe bends

connected to the pressure plate,
so that it can be moved freely
along the carrying bar.
6.1
Page 215
Opening 6
7. Inspect the sliding surfaces of the 10. Lubricate the threads with a thin
carrying bar and wipe clean layer of grease, e.g LUBRIPLATE
FGL-2 or equivalent.
8. Inspect pressure plate roller. 11. Mark the plate assembly on the out-
side by a diagonal line, or number
the plates in sequence.
9. Pull back the plastic covers on the 12. Measure and note the dimension A.
tightening bolts; brush the threads Compare with code plate and PHE
clean with a steel wire brush. documentation for this same serial
number.
6.2
Page 216
6 Opening
13 (See page 6.5) 14
P2 A10B TS6-M AM10 M10B

M10M
1 3
FG X X X X
FM X
FD X 4 2
13 (See page 6.5) 14
V8 P3 V13 V28 M10B M10BW M20-M

V20 M10M M10DW
E X 1 3
FD X
FG X X X X
FM X
VG X 4 2
13 (See page 6.5) 14
M3 P2 P3 V28 V45
EH X
VG X 1 3
VLCH X
FG X X
4 2
FD X X
13 (See page 6.5) 14

AM20
AM20B
AM20W
AM20S M6
MX25B A15BWA 15B TS20-M AM20DW M6M M15M
1 3
FG X X X X X X
FD X X X
FL X
FM X X X
4 2
FS X
M6/M6-MFG & MX25-BFM ONLY HAS ONE

BOLT TOP AND BOTTOM
6.3
Page 217
Opening 6
M20-M
FG
M20-MFG ONLY HAS ONE BOLT

TOP AND BOTTOM
M6
M15B AK20 M6M
M15F A20B T200 M6DW M30
FG X X
FD X
FM X
FS X
M6/M6-MFG ONLY HAS ONE BOLT TOP

AND BOTTOM
M10B M10BW
M10M
FD X X
A20B AK20 MX25B V110

T200
FD X X
FL X
FG X X
6.4
Page 218
6 Opening
13 14
AX30B
AX30BW V110
1 3
FG X
FD X
4 2
13 14
AX30B A35 AX35 M20M M30 MX25B V170

AX30BW A45 V280
1 3
FG X X X
FD X X X X X 5 6
HA X
FS X
7 8
NOTE: M30-FD, MA30-FG/FD, MX25-BFS, V280-FG/FD 4 2
and V170-FD have a twenty bolt or larger pattern, use this
picture only as a guide. Start sequence numbers 5 and 6
at the fourth bolt down on both sides.
15 16
1 3
ORDER BOLT NO. TO DIM.

1 1-2-3-4-5-6 1.05A
2 1-2-3-4 1.10A 4 2
3 1-2 OR 3-4 OPENING
13 If bolts are fitted with bearing boxes loosen and 16 Continue opening, alternately and diagonally.
remove them. If not fitted with bearing boxes, then
follow the pictures above. Note: Skewing of the Pressure Plate during opening
must not exceed 10 mm (2 turns per bolts) across the
14 Loosen the remaining bolts, alternately and width and 25 mm (5 turns per bolts) vertically.
diagonally, to bring length to 1.05A.
15 Remove bolts 5 and 6 completely.
6.5
Page 219
Removal and insertion of plates 6
1.
Brush the threads of the bolts clean,
using a steel wire brush
Lubricate the threads with a thin layer

2. of grease, e.g. LUBRIPLATE FGL-2
or equivalent.
3. 4.
REMOVAL OF PLATES
3. Push the pressure plate against the

support column.
4. Remove the plates. Stack them neatly on

a skid or pallet for easy transporting.
INSERTION OF PLATES
5. 5. Hang the plates with their backs towards the

pressure plate (the side without gasket).
6.6
Page 220
6 Closing
1. 4.
1. Check that all the sealing surfaces 4. Inspect the pressure plate roller.
(i.e. surfaces in contact with the heat Remove any debris from top surface of
transfer medium) are clean. carrying bar.
5. Check against the drawing or flow

sheet (provided with each heat
2. exchanger) to make sure that the
plates are hanging in the correct order.
6.
2. Check that the ring gaskets or liners,

when fitted in connections, are in
position and are in good condition.
6. Press the plate assembly together.
3.
7.
3. Clean and lubricate the sliding surfaces

of the carrying bar. 7. If the plates are correctly assembled,
the edges form a “honeycomb” pattern.
If the plate pack has been marked on

the outside (fig. 6) check this.
6.7
Page 221
Closing 6
8 (See page 6.11) 11
P2 A10B TS6-M AM10 M10B
M10M
FG X X X X
FM X
1 3
FD X
4 2
8 (See page 6.11) 11 14 (See page 6.11)

V8 P3 V13 V28 M10B M10BW M20-M
V20 M10M M10DW
E X
FD X 1 3
FG X X X X
FM X
VG X
4 2
8 (See page 6.11) 11 14 (See page 6.11)

M3 P2 P3 V28 V45
EH X
VG X
VLCH X 1 3
FG X
FD X X
4 2
8 (See page 6.11) 11 14 (See page 6.11)

5
AM20
AM20B
AM20W
AM20S M6
MX25B A15BW A15B TS20-M AM20DW M6M M15M
FG X X X X X X
1 3 1 3
FD X X X
FL X
FM X X X 4 2 4 2
FS X
M6/M6-MFG & MX25-BFM ONLY HAS ONE

BOLT TOP AND BOTTOM
6
6.8
Page 222
6 Closing
8 (See page 6.11) 11 14 (See page 6.11)
M20-M
FG 1 3
M20-MFG ONLY HAS ONE BOLT 4 2

TOP AND BOTTOM
8 (See page 6.11) 11 5 14 (See page 6.11)
M6
M15B AK20 M6M
M15F A20B T200 M6DW M30
FG X X 1 3 1 3
FD X
FM X
FS X
4 2 4 2
M6/M6-MFG ONLY HAS ONE BOLT TOP
AND BOTTOM
8 (See page 6.11) 11 5 14 (See page 6.11)
M10B M10BW
M10M
1 3 1 3
FD X X
4 2 4 2
8 (See page 6.11) 11 5 14 (See page 6.11)
A20B AK20 MX25B V110

T200
1 3 1 3
FD X X
FL X
FG X X
4 2 4 2
6.9 6
Page 223
Closing 6
8 11 14
7
AX30B
AX30BW V110
1 3 1 3
FG X
FD X 5 6
4 2 4 2
8 11
AX30B A35 AX35 M20M M30 MX25B V170

AX30BW A45 V280
1 3 1 3
FG X X X
FD X X X X X 5 6
HA X
FS X
7 8
NOTE: M30-FD, MA30-FG/FD, MX25-BFS, V280-FG/FD 4 2 4 2
and V170-FD have a twenty bolt or larger pattern, use this
picture only as a guide. Start sequence numbers 5 and 6
at the fourth bolt down on both sides.
14
ORDER BOLT NO. TO DIM.

1 1-2-3-4-5-6 1.05A
2 1-2-3-4 1.10A
3 1-2 OR 3-4 OPENING
Note: See next page for closing

instructions for all the models
6.10
Page 224
6 Closing
8. Place all the bolts that are fitted with bearing 14. Place the other bolts in position.
boxes in position. If not fitted with bearing boxes • Inspect the washers.
then follow the pictures for your specific model.
• When fully tightened, the bolts should all be
9. Brush the threads of the bolts clean, using a steel equally tensioned.
wire brush. • The difference between the plate pack lengths
measured at adjacent bolts should not exceed:
10. Lubricate the threads with a thin layer of grease, 2mm when dimension A is < 1000mm
e.g. LUBRIPLATE FGL-2 or equivalent.
4mm when dimension A is > 1000mm
11. Tightening is carried out alternately and diago- • The plate pack length at all bolts must not dif-
nally, as shown on the figure above. fer by more than 1%
• If the unit does not seal fully, it can be tightened
12. Check the dimension A during tightening at the
to the dimension A-1%.
positions of the bolts that are being used. Skewing
of the pressure plate during tightening must not
exceed 10mm (2 turns per bolt) across the width IF DIMENSION A IS NOT REACHED WITH APPLI-
and 25 mm (5 turns per bolt) vertically. CATION OF THE ABOVE STEPS:
• Check the number of plates and dimension A.
13. Nominal plate pack length A can be exceeded in
exceptional cases, the tightening can be stopped • Check that all the nuts and bearing boxes are
at the following dimensions running freely. If not, clean and lubricate or
replace.
Plate pack length/plat Plate pack length • Fit all the bolts, and tighten alternately.
> 4 mm A + 1%
> 3mm, < 4mm A + 1.5%
6.11
Page 225
Chlorine as growth inhibitor
Chlorine, commonly used as growth inhibitor in cooling

water systems, reduces the corrosion resistance of
stainless steels (including Hastelloy, Incoloy, Inconel
and SMO).
Chlorine weakens the protection layer of these steels

making them more susceptible to corrosion attacks
than they otherwise should be. It is a matter of time of
exposure and concentration.
In every case where chlorination of non-titanium

equipment cannot be avoided, ALFA LAVAL must be
consulted.
Contact the following address:

ALFA LAVAL
Heat Transfer Center
5400 International Trade Drive
Richmond, VA 23231
Phone (804) 222-5300
Fax (804) 236-3276
NOTE! Titanium is not affected by chlorine.
Page 226
7 Cleaning
INCRUSTATION - SCALING
• Calcium carbonate
• Calcium sulphate
• Silicates
CLEANING
Mechanical cleaning after opening.
1. 2.
1. Soft brush and running water. 2. High pressure hose.

NOTE! Avoid gasket damage.
NOTE!
3. Chemical cleaning of opened unit by Under no circumstances should
using: HYDROCHLORIC ACID be used
with STAINLESS STEEL PLATES
• Nitric acid and under no circumstances
should HYDROFLUORIC ACID be
• Sulfamic acid
used with TITANIUM PLATES.
• Citric Acid Water of more than 300 ppm
Chlorine may not be used for the
• Phosphoric acid
preparation of cleaning solutions.
• Complexing agents (EDTA, NTA)
It is very important that carrying
• Sodium polyphosphates
bars and support columns made of
aluminum are protected against
Concentration max 4% by wt%
chemicals.
Temperature max 140o F
7.1
Page 227
Cleaning 7
SEDIMENT
• Corrosion products
• Metal Oxides
• Silt
• Alumina
• Diatomic organisms and their
excrement of various colors.
CLEANING
1. 2.

3. Chemical cleaning of opened unit 4. The addition of surfactants can improve

by using: cleaning effect.
• Nitric acid
NOTE!
• Sulfamic acid
Under no circumstances should
• Citric Acid HYDROCHLORIC ACID be used with
STAINLESS STEEL PLATES and
• Phosphoric acid
under no circumstances should
• Complexing agents (EDTA, NTA) HYDROFLUORIC ACID be used with
TITANIUM PLATES. Water of more
• Sodium polyphosphates
than 300 ppm Chlorine may not be used
for the preparation of cleaning solutions.
It is very important that carrying bars and
Concentration max 4% by wt% support columns made of aluminum are
Temperature max 140o F protected against chemicals.
7.2
Page 228
7 Cleaning
GROSS FOULING
• Seaweeds
• Wood chips/fibers
• Mussels
• Barnacles
CLEANING: NOTE: BACKFLUSHING OF THE UNOPENED HEAT EXCHANGER

CAN SOMETIMES BE SUFFICIENTLY EFFECTIVE.
1. 2.

NOTE!
Under no circumstances should
HYDROCHLORIC ACID be used with
STAINLESS STEEL PLATES and
HYDROFLUORIC ACID be used with
TITANIUM PLATES. Water of more
than 300 ppm Chlorine may not be used
for the preparation of cleaning solutions.
It is very important that carrying bars

and support columns made of aluminum
are protected against chemicals.
7.3
Page 229
Cleaning 7
BIOLOGICAL GROWTH - SLIME
• Bacteria
• Nematodes
• Protozoa
CLEANING
1. 2.

NOTE!
3. Chemical cleaning of opened unit by Under no circumstances should
using: HYDROCHLORIC ACID be used with
• Nitric acid STAINLESS STEEL PLATES and
• Sulfamic acid HYDROFLUORIC ACID be used with
• Citric Acid TITANIUM PLATES. Water of more than
300 ppm Chlorine may not be used for
• Phosphoric acid the preparation of cleaning solutions.
• Complexing agents (EDTA, NTA)
It is very important that carrying bars
• Sodium polyphosphates and support columns made of aluminum
are protected against chemicals.
Concentration max 4% by wt%
Temperature max 140o F
7.4
Page 230
7 Cleaning
• Oil residues
• Asphalt
• Fats
CLEANING
1. Hydrocarbon-based deposits may be 2. Dry with a cloth or rinse with water.

removed by using a soft brush and a
PARAFFINIC or NAPHTHA-BASED
solvent (e.g. KEROSENE).
NOTE!
Gaskets in natural, butyl and EPDM
rubber swell in these media.
Contact time should be limited to 0.5

hour.
THE FOLLOWING SOLVENTS SHOULD NOT BE USED

• Ketones (e.g. Acetone, Methyletylketone, Methylisobutylketone)
• Esters (e.g. Ethylacetate, Butylacetate)
• Halogenated hydrocarbons (e.g. Chlorothene, Carbon tetrachloride, Freons)
• Aromatics (e.g. Benzene, Toluene)
7.5
Page 231
Regasketing 7
ALFA LAVAL has two types of glue for field repairs - GC11 and
GC8 for repairs and exchange of gaskets in plates. A special
glue is recommended for viton and silicone gaskets.
GC11 GC8
• A two-component, cold curing epoxy glue • A single-component rubber-based solvent

which gives a strong joint for higher adhesive.
temperatures.
• Is normally used for repair work in an
• Future removal of gaskets usually uncured condition.
requires heating or freezing of the joint.
• Can be used for operating temperatures
• The shelf life is limited to approx. 1 year below 200 F
when stored at room temperature but can be
prolonged when kept in a refrigerator. • For operating temperatures above 200° F
and oil coolers/heaters, the glued joints
should be cured at 200° F for one hour.
• Future removal of the gasket can usually

be carried out without heating of the cement
joint.
• The storage life at room temperature is

about two years. This period can be
extended after checking the glue.
SEPARATE GLUING INSTRUCTIONS WILL BE

DELIVERED TOGETHER WITH THE GLUE.
ALFA LAVAL RECONDITIONING SERVICE
In addition to supplying genuine gaskets for your possible bond strength between plate and
plate heat exchangers, we are able to provide a gasket, similar to the process used during
“SPECIALIZED PLATE RECONDITIONING manufacture. This is one reason why our
SERVICE” to quickly and efficiently meet your service is guaranteed.
service requirements.
In most cases our reconditioning service has
Our reconditioning service includes a liquid proved more economical and much faster when
nitrogen debonding process with chemical compared with on-site regasketing methods.
cleaning, crack detection and regasketing using
a special epoxy/phenolic resin adhesive. For further details, please contact your local
ALFA LAVAL REPRESENTATIVE.
This regasketing process requires special oven (See Section 1)
curing of the cement to ensure the strongest
7.6
Page 232
7 Regasketing
The Clip-on gasket -
a glue-free gasket system
The Clip-on gasket is attached to the plate by

two gasket prongs which slip under the edge of
the plate to hold the gasket securely in
alignment in the gasket groove.
The prongs are situated at regular intervals

around the periphery of the plate.
When the plate heat exchanger is then

assembled and tightened, the gasket provides
a tight seal around the plate.
NOTE!
Before closing of the equipment:

Check that the two gasket prongs
are in correct position.
The Clip-on gasket in the gasket groove.
7.7
Page 233
Regasketing of Snap-On Gaskets
THE PROCEDURES (2-7) ARE NOT NECESSARY FOR DOING A SMALL QUANTITY OF PLATES.
7
THESE PROCEDURES WILL INCREASE SPEED OF REGASKETING OF LARGE QUANTITIES OF PLATES.
PREPARATORY PROCEDURES
1. 5.
1. Pull the old gasket off the plate and 5. Remove the plate.
clean the groove, if necessary.
2.
6.
2. Place a flat sheet of plywood (some-

what larger than the PHE plate) on
the table.
6. Drill holes approx. 7mm dia and 10
3. mm deep in the plank at the marked
spots. The plank is now a practical tool
for regasketing of larger numbers of
plates.
7.
3. Place the PHE plate on the board
with gasket groove upwards and fix
firmly. Placing cylindrical pins in the
plank at the carrying bar slots.
4.
7. Replace PHE plate on the board in

exactly the same location as at 3
above.
4. Make marks in the plank at all loca-

tions for gasket “snap-on”.
7.8
Page 234
7 Regasketing of Snap-On Gaskets
FASTENING OF THE “SNAP-ON” GASKET
11.
8. Place the gasket, with the “snap-on” 11. Push the projection through the hole in
projections downwards, in the gasket the plate.
groove.
12.
9. Place the ring gaskets in the groove and 12. Remove the tool point, and the
fix them with the T-flap. projection is now “snapped on”.
13.
10.
13. Repeat for all projections, and the

gasket is “snapped on”.
NOTE!
BEFORE CLOSING OF THE EQUIP-
MENT: CHECK THAT THE T-FLAPS
ARE IN CORRECT POSITION.
10. Insert the tool point into the recess in the

projection.
7.9
Page 235
PARALLEL FLOW UNITS 7
The End Plate II Gasket is formed by cutting (2) channel gaskets

(as shown below) and gluing the gaskets to the first plate.
+ =
The (2) half channel gaskets should be glued to the end plate
with GC-8 glue: or double sided tape (GC-1). The (4) port
gasket areas are critical because these gaskets will be in
contact with the process fluids.
7.10
Page 236
7 DIAGONAL FLOW UNITS
The End Plate II Gasket is formed by cutting (2) channel gaskets

(as shown below) and gluing the gaskets to the first plate.
+ =
The (4) parts of the channel gaskets should be glued to the end
plate with GC-8 glue: or double sided tape (GC-1). The (4) port
gasket areas are critical because these gaskets will be in
contact with the process fluids.
7.11
Page 237
Fault detection 8
SYMPTOM
LEAKAGE between plates and frame.
ACTION CORRECTIONS
Mark with a felt tip or similar marker, mark the 1. • Relocate gasket.
area where the leakage seems to be, and open
the heat exchanger • remove foreign matter.
1. Investigate the gasket condition of the end
• replace connection lining if applicable.
plate and the connection if applicable, look
for dislocation, foreign objects, scars and Remove anything disturbing the joint
other damage to the gasket surfaces. between gasket and pressure plate surface.
2. Check the surface of the pressure plate for
A perforated end plate must be replaced.
unevenness, foreign objects sticking to it,
etc. that might spoil the joint between the
gasket and the adjacent surface.
3. Check the plate itself for cracks or holes.
SYMPTOM
LEAKAGE between flange and frame.
ACTION CORRECTIONS
1. Disconnect the flange, and look for 1. • Rearrange the pipe in order to eliminate
misalignment between flange and stress and to correct alignment.
connection, dislocated or damaged • relocate gasket
gasket, foreign objects on the surface of • replace damaged gasket
the gasket or the flange. • replace connection lining if applicable
• remove foreign matter from flange
and gasket
• reassemble, taking care to avoid
misalignment 8.1
Page 238
8 Fault detection
NOTE: On a Plate Heat Exchanger specially designed for high temperature duties, extreme
and sudden temperature drops may sometimes cause a temporary leakage. A typical
example is a sudden shutting-off of the hot medium flow. The heat exchanger will
normally seal again, as soon as the temperatures of the equipment have stabilized.
SYMPTOM
LEAKAGE between plates to

the outside.
ACTION CORRECTIONS
Mark the leakage area with a felt tip marker on 1. • Relocate gasket.
the two plates next to the leakage, check and • Re-cement loose gasket, if applicable.
note the length of the plate pack between inside • Replace damaged gasket.
frame plate and inside pressure plate, and then
2. A damaged plate must in most cases be
open the heat exchanger.
taken out for repair or replacement. If it is
a regular plate with 4 holes: take the dam-
1. Check for loose, dislocated or damaged aged plate and the 4-hole plate just in front
or just behind it out of the plate pack. The
gasket. heat exchanger can now be reassembled
and put back in service PROVIDED THE
2. Check for plate damage in the area, and PLATE PACK IS TIGHTENED TO A NEW
also check plate pack length against the MEASUREMENT, WHICH IS EQUAL TO
drawing to see if possible plate or gasket THE ONE ON THE DRAWING, REDUCED
damage could be caused by overtightening BY TWO TIMES THE SPACE REQUIRED
of the plate pack, or if the leakage itself may PER PLATE. CONTACT ALFA LAVAL FOR
ASSISTANCE IN THE RECALCULATION
simply be caused by insufficient tightening. IF NECESSARY.
The small reduction of the heat transfer
3. Check hanger recess at both plate ends area is normally of no importance, at least
for deformations, which could cause not for a short period of time.
misalignment between the plates. • Insufficient tightening must be corrected
- see the drawing.
4. Make sure that the plates are hanging
3. Damaged hanger recesses must be
correctly as A-B-A (see SECTION 4A or repaired if possible, or the plate replaced.
4B). For temporary arrangement with reduced
number of plates - see paragraph 2 above.
5. Check for perforation of the plate
(corrosion). 4. Incorrect sequence of plates must be cor-
rected (A-B-A-B-..). MAKE SURE THAT
NO PLATE HAS BEEN DAMAGED,
BEFORE REASSEMBLING THE PLATE
PACK!
5. Perforated plates must be replaced. For

8.2 temporary solution, see paragraph 2.
Page 239
Fault detection 8
SYMPTOM
LEAKAGE between plates.
ACTION CORRECTIONS
1. Check that the piping is connected to the 1. Relocate piping to correct connections.
heat exchanger at correct locations.
2. Open the lower connection on one side, raise

pressure on the other side and by looking
into the open connection try to detect any
liquid from the pressurized side leaking in,
and if so - approximately how far into the
plate pack the leakage is located. If no
leakage is detected, the reason for the mixing
of media must be sought elsewhere. (see
paragraph 5).
3. If a leakage was detected, note the position

of the leakage along the plate pack and then
open the plate heat exchanger.
4. Before starting on the plates themselves, 4. All deposits or material which can block
check that the corner areas between the ring the free exit from the area must be
and the field gaskets are clear, that the removed. If the leak channels of the
leakage slots are open. This ensures that any gasket have been destroyed, they must be
leakage is out of the plate heat exchanger reopened with a suitable tool, or the
and is to atmosphere. Therefore no pressure gasket replaced.
can build up to force the media across the
gasket sealing off the other liquid.
5. If it has not been possible to locate the 5. Plates with holes must be replaced. The
leakage as described in par. 2 above, it will PHE may be temporarily operated with a
be necessary to check each single plate for reduced number of plates. See “LEAK-
possible perforations, using any of the AGE between plates to the outside”.
following methods:
• put a strong light behind the plate and

watch for light coming through fine holes
or cracks.
• use a magnifying glass to check suspect
area.
• use a chemical penetrant, after having
cleaned the plates well.
8.3
Page 240
8 Fault detection
SYMPTOM
PRESSURE DROP PROBLEMS,
Pressure drop has increased

ACTION CORRECTIONS
Check that all valves are open including

non return valves.
Measure the pressure just before and

just after the heat exchanger, and the
flow rate. For viscous media a mem-
brane manometer with a diameter of at
least 30 millimeters should be used.
Measure or estimate the flow rate if pos-
sible. A bucket and a watch showing
seconds may be sufficient for small flow
rates. For larger flow rates, some type of
flowmeter is required. Compare the pres-
sure drop observed with the one speci-
fied for the actual flow rate. (see plate
print out)
1. If the pressure drop is higher than 1. See next paragraph.

specified, the temperature program
should also be checked:
1.1 If the thermometer readings 1.1 Open the PHE and take out
correspond to those specified, the whatever is clogging the
heat transfer surface is probably passage, or use the back-flush
clean enough, but the inlet to the system - if there is one - to rinse
heat exchanger may be clogged by out the cloggings.
some objects.
1.2 If the thermometer readings are 1.2 If a “cleaning-in-place” system

NOT corresponding to those is available, follow the
specified, heat transfer is obviously instruction and use it to wash
dropping below specifications, out the deposits. If not, open
because of deposits on the heat the PHE and clean the plates.
transfer surface, which at the same
time also increase the pressure
drop, since the passage becomes
narrower.
2. See pump instruction manual.
2. If the pressure drop corresponds to
the specifications, there is no need
for any action.
3. If the pressure drop is lower than

specified, the pump capacity is too
small or the observation is wrong.
8.4
Page 241
Fault detection 8
SYMPTOM: HEAT TRANSFER PROBLEMS
The heat transfer capacity is dropping
ACTION CORRECTIONS
Measure temperatures at inlet and outlets If the heat transfer capacity of the equipment
and also flow rates on both media, if has dropped below specified values, the
possible. At least on one of the media, both heat transfer surface must be cleaned. Either
temperatures and the flow rate must be use the “cleaning-in-place” arrangement if
measured. Check to see if the transferred provided or open the heat exchanger for
amount of heat energy corresponds to the visual inspection and manual cleaning.
specifications.
NOTE: Contact the Alfa Laval Sales &
If great precision is important, it will be Service Division for CIP recommendations
necessary to use laboratory thermometers (See Section 1).
with an accuracy of 0.2 degrees Fahrenheit,
and also to use the best equipment
available for flow measurements.
8.5
Page 242
9 Supplementary Parts
THE PARTITION PLATE - for special cases only.
If for instance, the thermal program requires that at

least one of the media is to flow in more than one
group through the plate package, there will be heat
transfer plates with fewer than 4 holes.
To prevent the thin metal collapsing under the

differential pressure, un-punched corners require
extra support.
The extra support is provided by a partition plate -

approximately the size of a channel plate - made of
about 1/4" - 3/4" thick plate material with lined holes
where a free passage is required.
The partition plate is suspended from the carrying

bar. Where partition plates are required, in units
with 8" ports or larger, there will be one at every
turning point in a multi-grouped plate package.
Example only
9.1
Page 243
ENSR00006 0207 Page 244
Page 245
Page 246
Data sheet
Pressure switches
Type RT
Description Type RT pressure switches incorporate a pressure
controlled, single-pole changeover switch where
the contact position depends on the pressure in
the connection port and the set value. The RT series
consists of pressure switches, differential pressure
switches and pressure switches for neutral zone
regulation. These units are for general use within the
industrial and marine sectors.
The RT series also covers safety pressure switches for
steam boiler plant.
For installations in which operation is particularly
critical from safety and economic points of view,
the use of fail-safe pressure switches is recommended.
The use of gold-plated contacts is also recommended
in such installations, provided operation involves only
a few switching cycles or low signal currents and
voltages.
Contents Page
Description ...............................................................................................................................................................................1
Survey of types, pressure ranges ......................................................................................................................................1
Technical data and code nos. all types ...........................................................................................................................2
Approvals ..................................................................................................................................................................................3
Technical data and material in contact with medium ..............................................................................................4
Dimension and weight .........................................................................................................................................................5
Installation ................................................................................................................................................................................6
Function ....................................................................................................................................................................................7
Function description fail-safe, TÜV ..................................................................................................................................8
Pressure switch for liquid level control...........................................................................................................................8
Pressure switch with adjustable neutral zone .......................................................................................................... 10
Differential pressure switches......................................................................................................................................... 11
RT spare parts and accessories ....................................................................................................................................... 13
Pressure switches type RT

Range
0 5 10 15 20 25 30 bar pe Type
bar
−1 → 0 RT 121
0 → 0.3 RT 113
0.1 → 1.1 RT 112
0.2 → 3 RT 110
Standard pressure switches −0.8 → 5 RT 1, 1A
0.2 → 6 RT 200
1 → 10 RT 116
4 → 17 RT 5, 5A
10 → 30 RT 117
0.1 → 1.1 RT 112
0 → 2.5 RT 33B, RT 35 W
Pressure switches for steam plant 1 → 10 RT 30 AW/ AB/ AS
approved by Vd TÜV
1→ 10 RT 116 W
2 → 10 RT 31 W/ B/ S
5 → 25 RT 19 W/ B/ S
5 → 25 RT 32 W/ B/ S
−0.8 → 5 RT 1 AL
Pressure switches with adjustable 0.2 → 3 RT 110 L
neutral zone 0.2 → 6 RT 200 L
4 → 17 RT 5 AL
10 → 30 RT 117 L
Δp = 0-0.9 bar Differential pressure switches −1 → 6 RT 266 AL
Δp = 0.1-1 bar −1 → 6 RT 263 AL
Δp = 0.1-1.5 bar −1 → 9 RT 262 AL/ A
Δp = 0.5-4 bar −1 → 18 RT 260 AL/ A
Δp = 0.5-6 bar −1 → 36 RT 260 A
Δp = 1-6 bar −1 → 36 RT 265 A
IC.PD.P10.B3.02 - 520B3058
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Data sheet Pressure switches, type RT
Technical data and code nos. When ordering, please state type and code The type designation for the letters below means:
number. A: Unit suitable for the medium ammonia
L: Unit with neutral zone
Pressure switches Preferred versions

Regulation Adjustable/ Max. Max. Pressure Code no.
range fixed operating test connection
(pe = mechanical pressure pressure ISO 228/1
effective differential PB p’
pressure)
Type
bar bar bar bar

−1 → 0 0.09 → 0.4 7 8 G⅜A 017-521566 RT 121
RT 113
0 → 0.3 0.01 → 0.05 0.4 0.5 G⅜A 017-519666 RT 113
for manual setting;
0.1 → 1.1 0.07 → 0.16 7 8 G⅜A 017-519166 017-519366 RT 112
cover with windows
0.1 → 1.1 0.07 7 8 G⅜A 017-519266 RT 112
0.2 → 3 0.08 → 0.25 7 8 G⅜A 017-529166 017-529266 RT 110
0.2 → 3 0.08 7 8 G⅜A 017-511066 RT 110
−0.8 → 5 0.5 → 1.6 22 25 7
/16-20 UNF 017-524566 RT 1
−0.8 → 5 0.5 22 25 7
/16-20 UNF 017-524666 RT 1
−0.8 → 5 0.5 → 1.6 22 25 G ⅜ A 1) 017-500166 RT 1A
−0.8 → 5 0.5 22 25 G ⅜ A 1) 017-500266 RT 1A
−0.8 → 5 1.3 → 2.4 22 25 G ⅜ A 1) 017-500766 RT 1A
0.2 → 6 0.25 → 1.2 22 25 G⅜A 017-523766 017-524066 RT 200
0.2 → 6 0.25 22 25 G⅜A 017-523866 017-523966 RT 200
1 → 10 0.3 → 1.3 22 25 G⅜A 017-520366 017-520066 RT 116
1 → 10 0.3 22 25 G⅜A 017-520466 017-519966 RT 116
4 → 17 1.2 → 4 22 28 G⅜A 017-525566 017-525366 RT 5
4 → 17 1.2 22 28 G⅜A 017-5094662) RT 5
4 → 17 1.2 → 4 22 28 G ⅜ A 1) 017-5046662) RT 5A
RT 116 4 → 17 1.2 22 28 G ⅜ A 1) 017-5047662) RT 5A
for tamper proof;
10 → 30 1→4 42 47 G ⅜ A 1) 017-529566 017-529666 RT 117
cap and blank cover 1)
Supplied with Ø 6/ Ø 10 mm weld nipple.
2)
With seal cap
Pressure switches with adjustable neutral zone

Regulation Mechanical Adjustable Max. Max. test
range differential neutral zone operating pressure Pressure
Code no. Type
(pe ) pressure, PB p’ connection
bar bar bar bar bar
−0.8 → 5 0.2 0.2 → 0.9 22 25 G ⅜ A 1) 017L003366 RT 1AL
0.2 → 3 0.08 0.08 → 0.2 7 8 G⅜A 017L001566 RT 110L
0.2 → 6 0.25 0.25 → 0.7 22 25 G⅜A 017L003266 RT 200L
4 → 17 0.35 0.35 → 1.4 22 25 G ⅜ A 1) 017L004066 RT 5AL
10 → 30 1 1 → 3.0 42 47 G⅜A 017L004266 RT 117L
1)
Supplied with Ø6/ Ø10 mm weld nipple
Differential pressure switches

Regulation Mechanical Adjustable Operation Max. Max. test Pressure
range differential neutral zone range operating pressure p’ connection
Code no. Type
Δp pressure, PB ISO 228/1
bar bar bar bar bar bar
0 → 0.9 0.05 0.05 → 0.23 −1 → 6 7 8 G ⅜ A 1) 017D008166 RT 266AL
RT 262 A 0.1 → 1.0 0.05 0.05 → 0.23 −1 → 6 7 8 G ⅜ A 1) 017D004566 RT 263AL
Differential pressure switch 0.1 → 1.5 0.1 0.1 → 0.33 −1 → 9 11 13 G ⅜ A 1) 017D004366 RT 262AL
0.1 → 1.5 0.1 −1 → 9 11 13 G ⅜ A 1) 017D002566 RT 262A
0 → 0.3 0.035 −1 → 10 11 13 G ⅜ A 1) 017D0027662) RT 262A
0.5 → 4 0.3 0.3 → 0.9 −1 → 18 22 25 G ⅜ A 1) 017D004866 RT 260AL
0.5 → 4 0.3 −1 → 18 22 25 G ⅜ A 1) 017D002166 RT 260A
0.5 → 6 0.5 −1 → 36 42 47 G ⅜ A 1) 017D002366 RT 260A
1.5 → 11 0.5 −1 → 31 42 47 G⅜A 017D002466 RT 260A
1→6 0.5 −1 → 36 42 47 G ⅜ A 1) 017D0072663) RT 265A
1)
Supplied with Ø 6/Ø 10 mm nipple. 2) Non-snap action contacts (see spare parts and accessories, contact system 017-018166)
3)
With SPST and SPDT contact system for alarm and cut off function at 0.8 and 1 bar
2 IC.PD.P10.B3.02 - 520B3058
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Technical data and ordering The designation letters mean: B: Safety units with external reset
A: Units suitable for the medium ammonia. S: Safety units with internal reset
W: Units for control purposes.
Pressure switches for steam plant, approved by Vd, TÜV Preferred versions
Regulation Adjustable/ Max. Max. Pressure Code no.
range fixed operating test connection
(pe = mechanical pressure pressure ISO 228/1
effective differential PB p’
pressure)
Type
bar bar bar bar
For rising pressure, approved acc. to PED

0.1 → 1.1 0.07 7 8 G ½A 017-528266 RT 112W
0 → 2.5 0.1 7 8 G ½A 017-528066 RT 35W
1 → 10 0.8 22 25 G ½A 017-518766 RT 30AW
1 → 10 0.4 22 25 G ½A 017-518866 RT 30AB
1 → 10 0.4 22 25 G ½A 017-518966 RT 30AS
5 → 25 1.2 42 47 G ½A 017-518166 RT 19W
5 → 25 1 42 47 G ½A 017-518266 RT 19B
5 → 25 1 42 47 G ½A 017-518366 RT 19S
For falling pressure

0 → 2.5 0.1 7 8 G ½A 017-526266 RT 33B
2 → 10 0.3 → 1 22 25 G ½A 017-526766 RT 31W
2 → 10 0.3 22 25 G ½A 017-526866 RT 31B
2 → 10 0.3 22 25 G ½A 017-526966 RT 31S
5 → 25 0.8 → 3 42 47 G ½A 017-524766 RT 32W
5 → 25 0.4 42 47 G ½A 017-524866 RT 32B
Pressure switch for low pressure steam plant (pressure monitoring)

0.1 → 1.1 0.07 → 0.16 7 7 G ½A 017-518466 RT 112
Approvals
RT 1 RT 1A RT 1AL RT 5 RT 30AW RT 31W RT 33B RT 110 RT 112 RT 113 RT 116 RT 117L RT 260A
RT 5A RT 30AB RT 31B RT 35W RT 117 RT 200L RT 262A
RT 121 RT 30AS RT 31S RT 112W RT 200 RT 265A
RT 19W RT 32W RT 260AL Approvals
RT 19B RT 32B RT 262AL
RT 19S RT 32S RT 263AL
RT 266AL
x x x x x x x x x x x x x CE marked acc. to EN 60947-4/-5
x x x x VD Tüv, Germany
x x x x Det Norske Veritas, Norway
x x x x Lloyds Register of Shipping, UK
x x x x x x Germanischer Lloyd, Germany
x x x x x Bureau Veritas, France
x x x x x x x x x x x x x Registro Italiano Navale, Italy
x x x x x x x x x x x x x RMRS, Russian Maritime Register of shipping
x x x x x x x Nippon Kaiji Kyokai, Japan
x x x x x x x x x x x x x CCC, China Compulsory Certificate
Note: in addition we refer to the certificates, the copies of which can be ordered from Danfoss
All RT are
• CE marked in accordance with EN 60947-4/-5 for sale in Europe
• Further, the RT 19 , RT 30, RT 35, and RT 112 series is CE markd in accordance with PED 97/23/EC, category IV, safety equipment.
IC.PD.P10.B3.02 - 520B3058 3
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Technical data Designation RT pressure switches

Ambient temperature In general −50 to 70°C ;
Diaphragm version −10 to 70°C
VD TÜV approved −40 to 70°C
Media temperature In general −40 to 100°C;
Diaphragm version −10 to 90°;
VD TÜV appr. -40 to 150°C, see page 6 (Steam plant)
Contact system
Single-pole changeover switch (SPDT)

Contact load Alternating current: Fig. 6
AC-1: 10A, 400 V
AC-3: 4A, 400 V
AC-15: 3A, 400 V
Contact material:
AgCdO Direct current:
DC-13: 12 W, 230 V
(see fig. 6)
Special contact system See “accessories” page 13
Cable entry 2 PG 13.5 for 6 - 14 mm diameter cables
Enclosure IP 66 acc. to IEC 529 and EN 60529. Units supplied with external reset.
IP 54. The thermostat housing is made of bakelite acc. to DIN 53470
Cover is made of polyamide.
Materials in contact with the medium
RT RT RT RT RT RT
RT RT RT RT RT RT
Material Part W .no. DIN RT 1 RT 1A RT 5 RT 5A 200/ 260A 262A/ 260AL 265A 263AL/
110 112 113 116 117 121
200 L 262 AL 266AL
Stainless steel 18/8 Bellows 1.4301 17440 x x x x x x x x x x x x x x x
Stainless steel 17/7 Spring 1.4568 17224 x x x x x
Brass Housing 2.0402 17660 x x x x x x x
Brass Bellows ring 2.0321 17660 x x x x x x x
Free-cutting steel Flare connection 1.0718 1651 x
Deep-drawn steel
(nick.plated surface) Housing 1.0338 1623 x x x x x x x x
Non-alli. carbon steel Weld connect. for

1.0402 1652 x x x x x x x
C 20 connection
Aluminium Gasket 3.0255 1712 x x x x x x x x
Case hardening steel Weld connection
1.0401 1652
C 15 Bellows connect.
Stainless steel Spring guide + screw 1.4305 17440
NBR rubber Diaphragm x
Deep-drawn steel Diaphragm housing
(surface DIN 50961 weld with welded 1.0338 1623 x
connection Fe/Zn 5C) connector
Spring thread Spring 1.1250 17223 x
Materials in contact with the medium Vd TÛV approved controls

RT 30AW
Material Part W.no. DIN RT 19W B,S RT 31W B,S RT 32W B,S RT 33B 35W RT 112 W RT 112
AB, AS
Stainless steel 18/8 Bellows 1.4301 17440 x x x x x x x
Stainless steel 17/7 Orifice 1.4305 17440 x x
Steel C 15 Connector 1.0401 1652 x x
Deep-drawn steel + Ni Bellows ring 1.0338 1623 x x x x x x
Stainless steel 17/7 Bellows spring 1.4568 17224 x x
Stainless steel Ring 1.4305 17440 x
Deep-drawn steel + Ni Housing 1.0338 1623 x x x x x x
Stainless steel Bellows connect. 1.4305 17440 x
Stainless, weldable
Connector 1.4301 17440 x x x x
free-cutting steel
Deep-drawn steel + Sn Spring guide 1.0338 1623 x
Brass Housing 2.0402 17660 x
Brass Bellows ring 2.0321 17660 x
4 IC.PD.P10.B3.02 - 520B3058
Page 250
Dimensions and weight
RT 5, 110, 112, 116, 117, 200

Special version with tamper
proof cap and blank cover
RT 13 RT 5, 110, 112, RT 5 RT 1A, 1AL

116, 117, 117L,
121, 200, 200L
RT 260A, 260AL RT 262A, 262AL, RT 5 RT 5A, 5AL

263AL
: External reset knob

only for RT...B
RT 30 AW, -B, -S L = 225

RT 19 W, -B, -S L = 228
RT 33 B, 35W L = 221
RT 112 W L = 210
RT 31 W-B, -S L = 212
RT 32 W-B, -S L = 212
Weight: approx. 1 kg
IC.PD.P10.B3.02 - 520B3058 5
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Installation RT units have two mounting holes which become Pressure connection
accessible when the front cover is removed. Units When fitting or removing pressure lines, the
fitted with switch 017-018166*) must be installed spanner flats on the pressure connection should
with the setting knob upwards. When installing be used to apply counter-torque.
differential pressure switches, the low pressure
Steam plant
side (marked LP) must be installed upwards. The
To protect the pressure element against tempera-
other pressure switches in the RT series can be
ture in excess to the maximum temperature of
installed in any position, expect that on plant
the medium 150°C (RT 113 90°C), the insertion of
subjected to severe vibrations it is advantageous
water-filled loop is recommended.
to have the screwed cable entry downwards.
Water systems
*) Contact system with snap-action contact. Water in the pressure element is not harmful, but
See spare parts and accessories, page 13. if frost is likely to occur a water-filled pressure
element may burst. To prevent this happening,
the pressure control can be allowed to operate
on an air cushion.
Media resistance
See table of materials in contact with the
medium. If seawater is involved, diaphragm
pressure switches types KPS 43, 45 and 47 are
recommended.
Pulsations
The pressure control must be connected in such
a way that the pressure element is affected by
pulsations as little as possible. A damping coil can
Fig. 1 Positioning of unit be inserted (see “Accessories”). With strongly
pulsating media, diaphragm pressure switches
types KPS 43, 45 and 47 can be advantageous.
Setting
5. Setting knob The range is set by using the setting knob (5)
9. Range scale while at the same time reading the scale (9). Tools
19. Differential setting
must be used to set pressure switches fitted with
disc
a seal cap.
In units having a fixed differential, the difference
between cut-in and cut-out pressures is of course
determined. On units having an adjustable
differential the front cover must be removed. The
differential disc (19) must be set in accordance
with the diaphragm.
Fig. 2
Selection of differential
To ensure that the plant functions properly, a
suitable differential pressure is necessary. Too
small a differential will give rise to short running
periods with a risk of hunting. Too high a differential
will result in large pressure oscillations.
Differential scale values are guiding
Fig. 3 Obtainable differential disc scale
6 IC.PD.P10.B3.02 - 520B3058
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Function a. RT 19, RT 30, and pressure switches with max. I. Alarm for rising pressure given at the set
reset range value.
When the pressure exceeds the set range value, II. Alarm for falling pressure given at the set
contacts 1-4 make and contact 1-2 brake. The range value minus the differential.
contacts changeover to their initial position when Units with max. reset can only be reset at a
the pressure falls to the range value minus the pressure corresponding to the set range value
differential (see fig. 4). minus the differential, or a lower pressure.
Scale setting −−−

Fig. 4. Contact function, setting for rising pressure
b. All other RT pressure switches I. Alarm for falling pressure given at the set range
When the pressure falls to the set range value, value.
contacts 1-2 make and contacts 1-4 brake. The II. Alarm for rising pressure given at the set range
contacts changeover to their original position value plus the differential.
when the pressure again rises to the set range Units with min. reset can only be reset at a
plus the differential (see fig. 5). pressure corresponding to the set range value
plus the differential.
Scale setting −−−

Fig. 5. Contact funktion, setting for falling pressure
Example 1 The range is 5-25 bar and the differential is fixed

An extra cooling water pump must start if the at approx. 1 bar. The range scale must be set at
cooling water pressure falls below 6 bar, and 17 bar. After cut-out of the burner, manual reset
must stop when the pressure exceeds 7 bar. is possible only when the pressure had fallen to
Choose an RT 116 with a range of 1-10 bar and an the setting of 17 bar minus the differential: in this
adjustable differential of 0.2-1.3 bar. case, 16 bar and below.
The start pressure of 6 bar must be set on the
range scale. The differential must be set as the
difference between the stop pressure (7 bar) and Example 3
the start pressure (6 bar) = 1 bar. According to fig. The min. permissible lubricating oil pressure for a
3, the differential setting disc must be set on 8. gear is 3 bar. Reset must not be possible until the
reason for oil pressure failure has been investigated.
Example 2 Choose an RT 200 with min. reset.
The burner on a steam boiler must cut out when The range value must be set while reading the
the pressure exceeds 17 bar. Automatic restart range scale. Manual reset is possible only when
must not occur. the pressure has reached 3.2 bar (the differential
Choose an RT 19B with external reset. If extra is fixed at 0.2 bar or higher).
safety is demanded, an RT 19S with internal max.
reset can be used.
IC.PD.P10.B3.02 - 520B3058 7
Page 253
Function description Fail-safe function for falling pressure

for RT units Fig. 5a shows a cross-section of a bellows element
TÜV approval for the RT 32W with fail-safe function for falling
pressure. On rising pressure the contact arm is
actuated to break the connection between
terminals 1 and 2.
On falling pressure the contact arm is actuated to
break the connection between terminals 1 and 4.
If a defect occurs in the bellows the setting spring
actuates the contact arm to break the connection
between terminals 1 and 4, as in the case of falling
pressure. This will occur irrespective of the pressure
on the bellows. Fig 5a
Fail-safe function for rising pressure
Fig. 5b shows a cross-section through a bellows
element for the RT 30W with fail-safe for rising
pressure. On rising pressure the contact arm is
actuated to break the connection between
terminals 1 and 2 . If a defect occurs in the inner
bellows the pressure is led to the outer bellows.
The outer bellows has an area three times as large
as the inner bellows. The connection between
terminals 1 and 2 becomes broken.
If a defect occurs in the outer bellows, there will be
atmospheric pressure in the gap between the two
bellows. This actuates the contact system to break
the connection between terminals 1 and 2. The
important factor with the double bellows design is
the vacuum between the two bellows, and that in Fig. 5b
case of bellows break, no media will leak into the
environment.
Pressure switches for liquid The RT 113 pressure switch can be used to control 3. Connection to the side of the tank with the RT 113
level control RT 113 the liquid level in open tanks. Fig. 6 shows in below the liquid level
principle, four different types of installation. Where possible, this form of connection should
be used. If an air-absorbing liquid like oil is
1. With air bell (see “Accessories”) involved, it is preferable to 1 and 2. The resulting
For control purpose, the air bell should be installed range setting is the distance from the liquid surface
20 to 40 mm below the lowest liquid level. In to the centre of the diaphragm housing.
addition, the tube between the RT 113 and the
air bell must be absolutely airtight. If only an 4. Connection in the tank with the RT 113 above the
indication is required, the bell can be placed 100 liquid level
mm below the max. level. The RT 113 must be set This method is for use with air-absorbing liquids
at 0 cm wg and the differential disc on 1. where connection type 3 is not possible. The
shortest horizontal tube length is determined as
2. Connection to the side of the tank with the RT 113 described in 2. A shut-off valve is installed
above the liquid level between the oil tank and water reservoir shown
The horizontal tube A must have a certain length so that impurities can be drained from the water
in relation to the vertical tube B in order to reservoir through a bottom drain plug. Fresh water
ensure reliable control. The length ofA can be can then be poured into the reservoir through a
found from fig. 7, using B and the range setting filling connector in its top.
pressure C.
8 IC.PD.P10.B3.02 - 520B3058
Page 254
Height from tank connector to pressure control
Min horizontal tube length
Fig. 6 Fig. 7
Application RT-L pressure switches are fitted with a switch

with an adjustable neutral zone. This enables the
units to be used for floating control.
The terminology involved is explained below.
Floating control
A form of discontinuous control where the
correcting element (e.g. valve, damper, or similar)
moves towards one extreme position at a rate
independent of the magnitude of the error when
the error exceeds a definit positive value, and
towards the opposite extreme position when the
error exceeds a definite negative value.
Hunting
Periodic variations of the controlled variable from
the fixed reference.
5. Setting knob
9. Range scale
Neutral zone
40. Neutral zone disc
The interval in the controlled variable in which
the correcting element does not respond
(see fig. 13).
The contact system in neutral zone units cannot

Fig. 8
be exchanged, as the contact system adjustment
is adjusted to the other parts of the unit.
IC.PD.P10.B3.02 - 520B3058 9
Page 255
Setting of neutral zone The range is set using the setting knob (5) fig. 8 The required neutral zone can be found in the
while reading the range scale (9). The pressure set diagram for the unit concerned. The position at
is the break pressure for contacts 1-4 (see fig. 13). which the neutral zone disc (40) must be set can
be read from the lower scale in the diagram. The
function can be seen in fig. 13.
Fig. 9 Fig. 10 Fig. 11 Fig. 12
Range setting
Inlet pressure
Differential (mechanical
differential) corresponds to the
least neutral zone setting.
a: The neutral zone.Inlet

pressure may vary within this
interval without resulting in a
make function 1-2 or 1-4.
Fig. 13
Example
Together with a VLT® static frequency converter, RT
200L neutral zone pressure switches can be used
for the infinite control of a pump in, for example, a
pressure boosting plant.
In this case, the pump must be up and down-regu-
lated at 32 and 25 m wg.
The RT 200L must be set using the setting knob (5) Pressure
fig. 8 page 9 at 3.5 bar (35 m wg) minus the fixed gauge
differential of 0.2 bar.
Signal lamp for
The range setting is 3.5 - 0.2 = 3.3 bar. falling and rising
Compressed
The neutral zone, 35 - 32 = 3 m wg, corresponding air pressure
to 0.3 bar, must be set on the neutral zone disc
(40) fig. 8 page 9. According to the diagram fig. 12
the disc setting is 1 or just over. A more accurate
setting can be obtained by using the test setup
Fig. 14
shown in fig. 14.
Test setup for setting the pressure control
10 IC.PD.P10.B3.02 - 520B3058
Page 256
Spare parts and accessories

Version Symbol Description Contact rating Code no.
Single-pole changeover switch (SPDT) with

terminal board proof against leakate current
Standard 017-403066
Fitted in all standard versions of type RT1).
Snap action changeover contacts.
For manual reset of unit after contact

changeover on rising pressure Alternating current:
With max. reset 017-404266
AC-1 (ohmic): 10 A, 400 V
For units with max. reset. AC-3 (inductive): 4 A, 400 V
AC-14/15 (coil/transformer): 3 A, 400 V
For manual reset of units after contact
Blocked rotor: 28 A, 400 V
changeover on falling pressure.
Direct current:
With min. reset 017-404166
DC 13/14: 12 W, 230 V
For units with min. reset.
Alternating current
Single-pole changeover switch (SPDT) with gold
AC-1 (ohmic): 10 A, 400 V
plated (oxide-free) contact surfaces.
AC-3 (inductive): 2 A, 400 V
Increases cut-in reliability on alarm and monitoring
Standard AC-14/15 1 A, 400 V 017-424066
systems, etc.
Snap action changeover contacts.
Direct current:
Terminal board proof against leakage current.
DC-13/14: 12 W, 230 V
Alternating current:
Single-pole changeover switch that cuts in two
AC-1(ohmic): 10 A, 400 V
Cuts in two circuits circuits simultaneously on rising pressure.
AC-3 (inductive): 3 A, 400 V 017-403466
simultaneously Snap action changeover contacts.
AC-14/15 2 A, 400 V
Terminal board proof against leakage current.
Direct current:
DC-13/14: 12 W, 230 V
Single-pole changeover switch that cuts out two
Cuts out two circuits circuits simultaneously on rising pressure. * If current is led through contacts 2 and 017-403666
simultaneously Snap action changeover contacts. 4, i.e. terminals 2 and 4 connected but
Terminal board proof against leakage current. not 1, max. permissible load is increased
to 90 W, 220 V - - -.
With non-snap action Single-pole changeover with non-snap action Alternating or direct current:
017-018166
changeover contacts changeover gold plated (oxide-free) contacts. 25 VA, 24 V
1
) At load types with low currents/voltages contact failure The switch contacts are shown in the position they
may occure on the silver contacts because of oxidation. assume on falling pressure/temperature, i.e. after
In systems where such a contact failure is of great downward movement of the RT main spindle.
importance (alarm etc.), gold plated contacts are
The setting pointer of the control shows the scale value
recommended.
Contact systems for neutral zone units are not at which contact changeover occurs on falling pressure/
available as spare parts. Exchange not possible, as the temperature. An exception is switch no. 017-403066
contact system adjustment is adjusted to the other with max. reset where the setting pointer shows the
parts of the unit. scale value at which contact changeover occurs on
rising pressure.
Switches
Version Symbol Description Contact rating Code no.
For Alarm application
For manual reset of unit after contact changeover on Alternating current:
With min. manual
falling pressure. AC-1 (ohmic): 10 A, 400 V 017-404766
reset
Gold plated (oxide-free) contact surfaces AC-3 (inductive): 2 A, 400 V
Full load current: 2 A, 400 V
AC-14/15: 1 A, 400 V
Blocked rotor: 14A, 400 V
For manual reset of unit after contact changeover on Direct current

With max. reset rising pressure. DC-13/14: 12W, 230 V 017-404866
Gold plated (oxide-free) contact surfaces
For control application
max. 100 mA / 30 V a.c./ d.c.
min. 1 mA / 5 V a.c. / d.c.
IC.PD.P10.B3.02 - 520B3058 13
Page 257
Part Description Qty. Code no.
Covers: Polyamide With window 5 017-436166

Cover
Colour: Pale grey RAL 7035 Without window 5 017-436266
Replacement Pale grey Ral 7035

Setting knob 30 017-436366
Seal cap to replace setting knob so that Black 20 017-436066

Seal cap
Setting can only be altered with tools
Seal screws for

1 + 1 017-425166
cover and seal cap
For all RT pressure switches with damping coil or other longer connections
Clamping band 10 017-420466
L= 392 mm
Conncetor with Pipe thread ISO 228/1, G⅜ connector, nipple and AL washer (10 mm ext. 6.5 mm
5 017-436866
nipple int. diam.) for welding or brazing on to steel or copper tubing
Connector 7/16 - 20 UNF connector for ¼ copper tube, brass, span of jaws 16 10 011L1101
Reducer Pipe thread ISO 228/1, G½A × G⅜, steel, span of jaws 22 1 017-421966
Pipe thread ISO 228/1, G⅜ × ⅛ - 27 NPT with copper washer, brass,

Adaptor 1 060-333466
span of jaws 22
Pipe thread ISO 228/1, G⅜ A × ¼ - 18 NPT with copper washer, brass,

Adaptor 1 060-333566
span of jaws 22
Pipe thread ISO 228/1, G⅜ × ¼ - 18 NPT with copper washer, brass,

Adaptor 1 060-333666
span of jaws 22
Adaptor Pipe thread ISO 228/1, G⅜ A - G ¼ A, brass, span of jaws 17 1 060-324066
Adaptor Pipe thread ISO 228/1, G ⅜ A × R ⅜ (ISO 7/1) brass, span of jaws 17 1 060-324166
0.50 m
Damping coil with 7/16 - 20 UNF connectors. Reducer code no. 017-420566 is 060-019066
1.00 m
necessary if the damping coil is to be used with RT units having a pipe thread 060-019166
Damping coil 1.50 m 1
ISO 228/1, G⅜ connection. Damping coils with several lengths of capillary tubes 060-019266
2.00 m
are available. Please contact Danfoss. 060-019366
Pipe thread ISO 228/1, damping coils with G⅜ connector and 1.5 m copper
Damping coil 1 060-104766
capillary tube. Standard washers are supplied.
Armoured Pipe thread ISO 228/1, damping coil with G⅜ connector and 1 m copper
1 060-333366
damping coil capillary tube. Standard washers are supplied.
® Danfoss A/S 09-07/ AC-BNM/mr
Air bell, 62 mm diam. ext. × 204 mm length. Pipe thread ISO 228/1,
Air bell for liquid
G⅜ connector and nipple (10 mm o.d./ 6.5 mm i.d.) for welding or brazing on to 1 017-401366
level control RT 113
steel or copper tubing. The air bell is of brass CuZn 37, W.no. 2.0321.
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products
already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
14 IC.PD.P10.B3.02-520B3058
Page 258
Page 259
Page 260
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Page 266
Page 267
MOUNTING INSTRUCTIONS FOR `FLOWTECH' FLOW SWITCHES MUKUND
FOR TYPE : FM4 GP, FM4 FP, FM4 FG, FM4 AF, FM4 CF, FM4 WP AND FM4 WP S
AN ISO 9001 : 2008 CERTIFIED COMPANY
We thank you very much for selecting Mukund make `FLOWTECH' flow switch, which has already
established its superiority and operational reliability. Thousands of our flow switches are working in India and other
countries. This is a versatile flow switch designed to accept different pipe sizes, within the same basic frame,
simply by changing a flapper of proper length. The simple and robust construction ensures practically no failures.
To get the best out of the flow switch, we request you to carefully go through the mounting instructions and mount
the flow switch accordingly.
MECHANICAL
1) Ensure that the flow switch is not damaged in transit.

2) Mount the flow switch such that actual direction of flow of flowing fluid is same as
per the arrow marked on the flow switch. See Fig. 1.
3) Mount the flow switch in such a way, so that it is easily accessible and there must
be sufficent space around for easy installation and maintenance.
4) Do not install flow switch in pipe zones with vibrations and shocks.
5) Mount the flow switch such that its flapper is at right angle to the flow of flowing
fluid.This is very important for proper operation of the flow switch . See Fig. 1. FLOW
6) We recommend you to put a strainer of proper size, in the pipe line, long before the
flow switch. FIG. - 1
7) For correct operation of the flow switch keep a straight length of minimum 6 X D from both sides of the flow
switch. ( D = Internal diameter of the pipe line.) See Fig. 2.If it is not possible to maintain required strarght
lengths, insert flow laminators before and after the flow switch. For it's details please contact us.
8) Do not try to mount a flow switch which is not sutable for the
pipe size. Such a flow switch will not give you
a proper service.
FLOW 9) Insert the flow switch by welding a 1" B.S.P. theaded socket
D
to the pipe line. Keep a distance of 25 mm between top of

6xD 6XD the socket and top of the pipe line. See Fig. 3.
FIG. - 2
10) Keep a clearance of about 4 to 5 mm between bottom
25 MM
of the pipe line and bottom of the flapper and manually

ensure that the flapper moves free without any
obstruction. If necessary trim the flapper to required
clearance. See Fig. 4.
11) Ensure that the pipe is always full with the
flowing fluid.
FIG. - 3
VERTICAL MOUNTING OF FLOW SWITCH
Because of space limitations it is sometimes necessary that the only available installation may be in a vertical
section of the pipe line. The flow switches in FM4 series will generally operate satisfactorily when installed on a
vertical pipe with upward or downward flow, provided there is no unusual amount of dirt or sediment in the fluid.
We advice to hold the flow switch in the position to be installed and manually check for `Flow and no Flow' click by
pressing and releasing the paddle in the direction of flow.
LOADING SCREW
SET POINT ADJUSTMENT FOR CHANGING
SET-POINT
The set point is factory set for the specified flow or no flow conditions and is
locked by locking the loading screw. However the flow switch can be, set to a
different set point, at site, as follows. See Fig. 4.
1) TO SHIFT THE SET POINT TO HIGHER FLOW RATES : Unlock the loading screw,
by unscrewing the locking nut, turn loading screw clockwise and re-lock. FLOW
2) TO SHIFT THE SET POINT TO LOWER FLOW RATES : Unlock the loading screw,
KEEP CLEARANCE
by unscrewing the locking nut, turn loading screw in anti-clockwise direction and OF 4 TO 5 MM
re-lock. FROM BOTTOM OF
PIPE LINE
FIG. - 4
Above adjustments are approximate but very useful as last minute solution.
Page 268
AVERAGE FLOW RATES IN LITERS PER MINUTE TO ACTUATE SWITCH
PIPE SIZE 25 NB 32 NB 40 NB 50 NB 65 NB 80 NB 100 NB 125 NB 150 NB

MINIMUM FLOW 25 35 50 70 90 110 150 220 300
ADJUSTMENT
(FACTORY SET) NO FLOW 15 20 30 40 50 50 80 110 150
MAXIMUM FLOW 40 65 95 120 160 200 280 430 630
ADJUSTMENT NO FLOW
35 55 80 90 140 180 240 350 470
ELECTRICAL
1) The flow switch is provided with a micro switch with one set of change over contact. Its rating is 230 Volts, 5 Amps,
50 Hz.
2) We expect you to use these contacts in the control circuit and not in main power circuit. This will prolong contact
life to a great extent. Also the life of the flow switch increases to a great extent. Hence we specify the duty of the
flow switch as `Pilot Duty’.
3) While making connections do not disturb the setting of the micro switch. This can be achieved by using small but
adequate force while making connections.
4) Contact multiplication can be achieved by incorporating an auxiliary relay, in the control circuit,
with sufficient number of contacts.
5) Depending on the application connect the flow switch as per Fig. 5 or Fig. 6.
PREVENTION OF HUNTING EFFECT AND NUSANCE TRIPPING.
Some time, due to system pulsation the paddle of the flow switch flutters, giving unwanted control signals. We
recommend to incorporate a timer, in the control circuit, having a time delay of 3 to 5 seconds. This will prevent
nusance trippings
MUKUND MUKUND
FLOW FLOW FLOW FLOW

CLOSES OPENS CLOSES OPENS
COMMON CIRCUIT CIRCUIT COMMON CIRCUIT CIRCUIT
1 2 3 1 2 3
LOAD
LOAD
LINE
LINE
FIG. - 5 FIG. - 6
OVERALL DIMENSIONS. ALL DIMENSIONS ARE IN MM.
FLAME PROOF ENCLOSURE GENERAL PURPOSE ENCLOSURE
TYPE : FM4 FP TYPE : FM4 GP.
150 105 90
114d
61
80
66
171
218
1" B.S.P.
53
CABLE ENTRY
53
S.S. FLAPPER.
S.S. FLAPPER
38
1" B.S.P.
38
MUKUND ELECTRICALS
“FLOWTECH HOUSE”
139, Industrial Estate Extension,
Hotgi Road,
SOLAPUR - 413 003. MAHARASHTRA - INDIA.
Phone : +91 217 2602488.
Fax : +91 217 2602488.
E-mail : info@flowtech.co.in
: mukund.electricals@gmail.com
Page 269
Data sheet
Pressure and temperature switches, type KP

Features • Wide regulating range
• Small dimensions
Space-saving, easy to install in panels
• Shock and impact resistant
• Ultra-short bounce time.
Limits wear to an absolute minimum and increases
reliability
• Snap action electrical contacts minimize chatter,
bounce, and wear, and ensure long term electrical and
mechanical reliability
• Electrical connection from front of the unit.
Makes rack mounting easier and also saves space
• Suitable for alternating current and direct current
KP pressure switch with • Manual trip allows electrical function test without
manual reset tools
• Versions with automatic and manual reset available
Contents Pressure switches KP 34, KP35, KP36 and KP37 Page

Features ......................................................................................................................................................................................... 1
Contents .......................................................................................................................................................................................... 1
Description ..................................................................................................................................................................................... 2
Approvals ....................................................................................................................................................................................... 2
Ordering .......................................................................................................................................................................................... 2
Technical data ............................................................................................................................................................................... 2
Contact system and application ........................................................................................................................................... 2
Setting ............................................................................................................................................................................................ 3
Terminology ................................................................................................................................................................................. 3
Design and function ................................................................................................................................................................... 4
Dimension and weight ............................................................................................................................................................... 4
Temperature switches KP79 and KP81

Features ........................................................................................................................................................................................... 5
Description ..................................................................................................................................................................................... 5
Approvals ........................................................................................................................................................................................ 5
Ordering .......................................................................................................................................................................................... 5
Technical data ................................................................................................................................................................................ 5
Contact system and application ............................................................................................................................................. 6
Design and function.................................................................................................................................................................... 6
Setting .............................................................................................................................................................................................. 7
Terminology ................................................................................................................................................................................... 7
Charge ............................................................................................................................................................................................. 7
Dimensions and weights .......................................................................................................................................................... 8
Accessories for KP pressure and temperature switches ................................................................................................. 8
IC.PD.P10.L3.22 - 520B3031
Page 270
Data sheet Pressure switches type KP34, KP35, KP36 and KP37
Description Danfoss KP switches are used for regulating, The pressure switches are fitted with single-pole
monitoring and alarm systems in the industry. changeover switch (SPDT). The position of the
They provide automatic limit protection or manual switch depends on the setting of the pressure
reset limit protection for pressure systems. Can be switch and the pressure in the connector.
used with steam, air, gaseous and liquid media.
Approvals UL listed for USA and Canada according to UL 353

and UL 873.
CE marked in accordance to EN 60947-4/05 .
Ordering Pressure switches, type KP

Range Differential Pressure Max. operating Min. burst
Type Reset Code nos
[psig] [psi] connection pressure [psig] pressure [psig]
KP 34 2....15 2....6 Autmatic 58 435 060-214966
KP 34 2....15 3 fixed Manual 58 435 060-214866
KP 35 6....50 6....32 Automatic 145 1015 060-215166
KP 35 6....50 7 fixed Manual 145 900 060-215066
¼” 18 NPT
KP 36 15....150 10....58 Automatic 245 1015 060-214466
KP 36 15...150 10 fixed Manual 245 1015 060-214566
KP 37 58....300 26....45 Automatic 405 1450 060-214666
KP 37 58....300 43 fixed Manual 405 1450 060-214766
Technical data Ambient temperature Contact system

-40 to 150 ˚F (175 ˚F for short period of time) Single pole changeover switch (SPDT)
Media temperature Contact material AgCdO
-40 to 212 ˚F Contac load
Parts in contact with medium: Alternating current
Bellows: stainless steel FLA = 16 A @ 120 Vac
Pressure connection: free-cutting steel, 8 A @ 240 Vac
nickel plated LRA = 96 A @ 120 Vac
Enclosure 48 A @ 240 Vac
NEMA 1 Direct current
Wire dimension 240 VDC: 12W pilot duty
12 AWG max Cable entry
Integral ½ in. female NPSM swivel cable
connector, allows direct attachenments of ½ in.
male pipe thread connector
Contact system and Switch type - single pole double throw Switch action Application
application
1. Terminals 1 - 4 close high and open low 1. Low pressure
Terminals 1 - 2 can be used as low pressure alarm cut-out
2. Terminals 1 - 2 open high and close low 2. High pressure

Terminals 1 - 4 can be used as high pressure alarm cut-out
2 IC.PD.P10.L3.22 - 520B2557
Page 271
Setting Cut-in and cut-out pressures of the system Pressure switches with manual reset
should always be checked with an accurate
pressure gauge. Set the cut-out pressure on the RANGE scale.
Pressure limiters can be manually reset by
Pressure setting for switches with automatic pressing reset button when the pressure is equal
reset. to the cut-out pressure minus fixed value of the
differential.
Set the cut-out pressure on RANGE scale and
differential on DIFF scale.
Note:
Restart pressure is equal to cut-out pressure minus
differential value.
Terminology Set point FLA -Motor Full Load Amperes

A predetermined value to which a switch is The current rating, in amperes, of the motor when a
adjusted and at which it performs its intended full load is applied to it for work being done.
function.
LRA - Locked Rotor Amperes
Reset The current drawn, in amperes, by an electric motor
1. Manual reset with the shaft or rotor stopped and locked in
A unit with manual reset can only be restored to position.
operational mode by activation of the external
reset button.
2. Automatic reset
A unit with automatic reset is restored to
operational mode automatically.
Maximum working pressure

The maximum permissible pressure for safe
functioning of a heating system or any of its part.
Snap function
A specific contact force is maintained until snap is
initiated. The time over which contact force
reaches zero is a few milliseconds; therefore,
contact bounce cannot occur as a result, for
example, of slight vibrations before cut-out.
The snap-action contact system will continue to
function even when micro-welds are created
between the contacts during cut-in.
The force created to separate the contacts is strong,
and instantly shears off all contact surface welds that
have been created as the result of
cut-in action.
These design features ensure that the cut-out point
of the KP switch remains very accurate and
completely independent of the magnitude of the
current load.
IC.PD.P10.L3.22 - 520B2557 3
Page 272
Design and function

1. Range setting spindle
2. Differential setting spindle
3. Main arm
4. Main spring
5. Differential spring
6. Bellows
7. Pressure connector
8. Contact system
9. Switch terminals
10. Ground terminal
11. Cable entry: ½ in. female cable gland
12. Tumbler
13. Locking screw
14. Manual reset
15. Distance plate
Key sketch of KP pressure switch
The contact system of KP switches has a snap-

action function and the bellows moves only when
cut-in or cut-out set point is reached.
The design has the following advantages:
- higher contact load
- ultra short bounce time
- long mechanical and electrical lifetime
- high resistance to vibrations and pulsations
Simplified drawing of KP pressure switch without front

cover and scale. Version with manual reset.
Dimensions and weight
KP 35, KP 36 and KP37 KP 34 pressure switch

(all dimensions in inches) (all dimensions in inches)
Approximate weight: 0.83 lb Approximate weight: 0.9 lb
4 IC.PD.P10.L3.22 - 520B2557
Page 273
Features • Wide regulating range

• Small dimensions
Space saving, easy to install in panels
• Shock and impact resistant
• Ultra-short bounce time
• Snap action electrical contacts minimize
chatter, bounce, and wear,
and ensure long term electrical and
mechanical reliability
• Electrical connection at front of the unit.
Makes rack mounting easier and save space.
• Suitable for both alternating and direct current
• Screwed wiring, makes rewiring
easy
• Manual trip allows electrical function
test without the tools
• Version with automatic and manual reset
available
Description Danfoss KP temperature switches are used for The position of the switch depends on the
regulating, monitoring and alarm systems in thermostat setting and sensor temperature.
industry. A KP thermostat can be connected and switch to
KP thermostats are temperature-operated electric single-phase alternating current motors of up to
circuit breakers. The thermostats are fitted with 2 kW.
single-pole changeover switch (SPDT).
Approvals UL listed for USA and Canada according to UL 353

and UL 873.
CE marked in accordance to EN 60947-4/-5 .
Ordering Temperature switches, type KP

Capillary tube Max. sensor
Setting range Differential
Type Reset function length temperature Code number
[ºF] [ºF]
[in] [ºF]
KP 79 122 to 210 9 to 27 Auto 300 060L223866
KP 79 122 to 210 10 fixed Manual 300 060L223966
KP 79 140 to 240 9 to 27 Auto 300 060L224266
80
KP 81 176 to 240 9 to 45 Auto 480 060L224066
Technical data Ambient temperature Cable entry

-40˚F to 150 ˚F (for short periods up to 175 ˚F) Integral ½ in. female NPSM swivel cable
Sensor material connector, allows direct attachenments of ½ in.
Tinned copper Cu/Sn5 male pipe thread connector
Contac system Wire dimension
SPDT – single pole double throw 12 AWG max
Contact load Enclosure
Alternating current NEMA 1
FLA = 16A @120 Vac
LRA = 96A @ 120 Vac
Direct current
240 Vdc: 12 W pilot duty
IC.PD.P10.L3.22 - 520B2557 5
Page 274
Contact system and Switch type - single pole Switch action Application
application 1. Terminals 1 - 4 close high and open low 1. Low temperature cut-out
Terminals 1 - 2 can be used as low
temperature alarm
2. Terminals 1 - 2 open high and close low 2. High temperature cut-out
Terminals 1 - 4 can be used as high
temperature alarm
Design and function 1. Temperature setting spindle

2. differential setting spindle
3. Main arm
4. Main spring
5. Differential spring
6. Bellows
7. Temperature sensor
8. Contact system
9. Terminals
10. Ground terminal
11. Cable entry: ½ in. female cable gland
12. Tumbler
13. Locking screw
14. Manual reset
15. Distance plate
Key sketch of KP79, KP81 temperature switches
The contact system of KP switches has a snap-

action function and the bellows moves only
when cut-in or cut-out set point is reached.
The design has the following advantages:
- higher contact load
- ultra short bounce time
- long mechanical and electrical lifetime
- high resistance to vibrations and pulsations
Simplified drawing of KP temperature switch

without front cover and scale.
Version with manual reset.
6 IC.PD.P10.L3.22 - 520B2557
Page 275
Data sheet Temperature switches type KP79 and KP 81
Temperature switches with automatic reset Temperature switches with manual max. reset
Setting
Set the cut-out temperature on the RANGE scale and Set the cut-out temperature on the range scale.
differential on the DIFF scale. The differential is fixed.
Restart temperature is equal to the cut-out
temperature minus differential value. Restart the system by pressing the reset button after
the temperature of the sensor falls to a value equal to
Please note that the differential scale is only a the range scale setting minus the fixed differential.
reference. The exact value of distances on the scale
depends on where in its range the switch cut-in is
set. Use the differential scale as a guide, and if
precise function is required, establish the
differential setting by comparing function with an
accurate thermometer in the controlled zone.
Terminology Differential Reset

The differential is the difference between the cut-in 1. Manual reset:
and cut-out temperatures. units with manual reset can only be restarted
The differential is necessary for satisfactory after activation of the reset button. On max.
automatic operation of the controlled system. reset units the set value is equal to cut-out
Mechanical differential (intrinsic differential). value for rising temperature.
The mechanical differential is the differential set by 2. Automatic reset:
the differential spindle. These units are automatically reset after
operational stop.
Snap function
A specific contact force is maintained until snap is FLA - Motor Full Load Amperes
initiated. The time over which contact force reaches FLA is the largest current that a motor or other de-
zero is a few milliseconds; therefore, contact bounce vice is designed to carry at rated voltage and other
due to vibration, for example, cannot occur at cut- specific conditions. Also often called current at rated
out. conditions.
The snap-action contact system will continue to
function even when micro-welds are created LRA - Locked Rotor Amperes
between the contacts during cut-in. The force LRA is the current in amperes drawn by an electric
created to separate the contacts is strong enough to motor with the shaft or rotor immobilized.
instantly shear off all contact surface welds that may
have been created by cut-in action.
Charge Sensors with adsorption charges contain a super-

heated gas together with a solid having a large
Adsorption charge adsorption surface. The sensor can be placed in zones
that are warmer or colder than the switch housing
and capillary tube, but variations of more than +70°F
may influence scale accuracy.
Bellows
Capillary tube
Sensor
IC.PD.P10.L3.22 - 520B2557 7
Page 276
Data sheet Pressure and temperature switches type KP
Dimensions and weights
Sensor pocket for KP79/

KP81,
code no.: 017-437866
Sensor of KP79/ KP 81,

Material: tinned copper
CuSn5
Part Symbol Description Code no.

Accessories
for KP pressure and
temperature switches
Brackets with
mounting screws
Wall bracket 060-105266
and washers for
Angle bracket 060-105366
pressure and
4 screws 10-32 UNC + 4 washers 060-105166
temperature
switches
When the bracket is mounted

Top cover for on the back plate of the housing,
pressure and the grade of enclosure of the KP
060-109766
temperature switch is IP 44. Top cover covers
switches the setting spindles.
Brass made
Sensor pocket, gasket and
sensor
union nut to screw into ½ in.
pocket for KP 017-437866
connector welded onto tubes,
temperature
containers etc.
switch
Knob for KP
temperature 060-106366
switch
©Danfoss A/S 07-2007, AC-DSL, mr
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products
already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
8 IC.PD.P10.L3.22 - 520B3031
Page 277

Operating Instructions: Sugar Mill Drive Gear Box Flender Duored SVVL 700

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Operating Instructions: Sugar Mill Drive Gear Box Flender Duored SVVL 700

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Operating Instructions

Customer M/s Siemens Mexico

SUGAR MILL DRIVE GEAR BOX

FLENDER DUORED SVVL 700

Siemens Ltd,309/2,‘A‘ Block 100,Chettipedu Village Datum/Date Name Abt./Dept.

Please quote in correspondence : TD 3005260862-10

Technical data TD 3005260862 4

Siemens Ltd,309/2,‘A‘ Block 100,Chettipedu Village Datum/Date Name Abt./Dept.

Please quote in correspondence : TD 3005260862-10

Order No. - Item No. : 3005260862-10

Actual ratio : 199.39 : 1

Assembly and operating instructions

FLENDER gear units

Duored-2 helical­gear unit 2

WARNING! Imminent personal injury!

WARNING! Imminent damage to the product!

WARNING! Hot surfaces!

Earth connection point Air relief point yellow

Oil­filling point yellow Oil­draining point white

Oil level red Oil level red

Lubrication point red Apply grease

Lifting eye Eye bolt

Alignment surface, horizontal Alignment surface, vertical

1.1 General technical data

Fig. 1: Rating plate gear unit

① Company logo ⑧ Speed n2

② Order number, item, sequence number, ⑨ Oil data

③ Total weight in kg ⑩ Instructions number(s)

④ Special information ⑪ Special information

⑤ Type, size *) ⑫ Manufacturer and place of manufacture

⑥ Power rating P2 in kW or output torque T2 in Nm ⑬ Country of origin

1.1.1 Ambient atmosphere and ambient temperature

Fig. 2: Gear­unit types

Tel.: +49 (0)2871 / 92‐0

3.1 Obligations of the user

• No electrical welding work must be done at all on the drive.

• Removed safety equipment must be re­installed prior to starting up.

In case of hot surfaces (> 55 °C) there is a risk of burns!

During oil changes there is a risk of scalding from escaping oil!

Caution, serious danger!

Observe the instructions in section 3, "Safety instructions"!

Fig. 3: Transport symbols

Fig. 4: Attachment points

4.3 Storing the gear unit

Do not stack gear units on top of one another.

Ensure that the coat is not damaged!

The adhesive tape must not be removed before start­up.

Duration of protection Preservative agent Special measures

bis 6 Monate None

- Close all holes in the gear unit.

1) in case of Tacolab seal only (see item 5.7.3)

Duration of protection Preservative agent Special measures

bis 6 Monate None

- Close all holes in the gear unit.

1) In case of Tacolab seal only (see item 5.7.3)

Remove any oil spillage immediately with an oil­binding agent.

• Place inspection and/or assembly cover including seal on the housing.

• This procedure must be repeated and documented every 6 months.

4.4.3 Exterior preservation

Duration Preservative Layer

Observe the instructions in section 3, "Safety instructions"!

It is designed for installation in the horizontal position.

The gear unit can be operated in both directions of rotation.

Duored-2 helicalgear unit 2

Oilfilling point yellow Oildraining point white

Fig. 2: Gearunit types

• Removed safety equipment must be reinstalled prior to starting up.

The adhesive tape must not be removed before startup.

Remove any oil spillage immediately with an oilbinding agent.

Airrelief point: yellow Oildraining point: white

Oilfilling point: yellow Lubrication point: red

Fig. 6: Gearunit features

In case of gear units with addon oilsupply

Fig. 7: Radial shaftsealing ring

5.12 Oillevel monitoring system

5.13 Bearingmonitoring system

Protect shaftsealing rings from damage and heating to over + 100 °C

• Align gear unit horizontally by in and output shafts:

7.1 Procedure before startup

• Place suitable containers under the oildraining points.

• Close the oildrain cock.

• Check the oil level in the gearunit housing.

Remove any oil spillage immediately with an oilbinding agent.

• Leaktightness of the oilcooling or oilsupply lines.

7.2.1.1 Gear unit with oilsupply system

The maximally permissible oilsump temperature is 90 °C (for mineral oil) or 100 °C

Remove any oil spillage immediately with an oilbinding agent.

Remove any oil spillage immediately with an oilbinding agent.

• Screw in the oildrain plug.