BFP Hydrocoupling Manual by VOITH

Voith Turbo VOITH
Technical Documentation
Instruction Manual
Code
SEC S6 Indonesia Pelabuhan
Geared variable speed coupling

R 15 K400 M r.'Yf'·"
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2#: 23 LAJ10AP001
3#: 33 LAJ10AP001
Techn. Documentation No. 91800037910_BA1_en
Revision 0
Appendix_A_
Appendix_B_
VOITM
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 Imprint
If you have questions regarding the Geared variable

speed coupling, please contact the Service Center
(aira) of the Product Group 'Variable Speed Drives'
(stating the serial number) at Voith Turbo GmbH &
Co. KG Crailsheim
Voith Turbo GmbH & Co. KG

P.O. Box 15 55
0-74555 Crailsheim
Switchboard:+497951 32-0
Main fax:+49 7951 32-650
E-mail: regelbare.antriebe@voith.com
Service Center - Variable Speed Drives
www.voith-coupling-service.com
E-mail:
service.regelbare.antriebe@voith.com
Tel. +49 7951 321666
Fax +49 7951 32903
This Instruction Manual describes the technological
level of the Geared variable speed coupling at the
time of delivery.
Subsequent changes in the design of the Geared va
riable speed coupling are not incorporated in this In
struction Manual.
©2010
This Instruction Manual is protected by copyright
laws. It cannot be translated, duplicated (mechani
cally or electronically) in whole or in part, or passed
on to third parties without the written approval of the
publisher.
Date of issue: 2010-11-05
Techn. Documentation No. 91800037910_BA1_en
Version 1
Printed in Germany
VOITH
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 Version· Log
Version - Log
Version 1.00
- Amendments, exchange
of chapters/ sheets
of the instruction manual.
- Addendums within an
instruction manual
- Complete
exchange of the whole
instruction manual
Overhaul Version Revision Date
0 1.00 First edition of disassembly / reassembly in 2010-11-05

struction
Date Author Head of product group
2010-11-05 airpd / HSr airev / Graf

airek / Hofmann
iii
VOITN General Information on the
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 Instruction Manual
General information on the Instruction Manual

This Instruction Manual contains important information on how to operate the Geared Economical
variable speed coupling safely, properly and economically. Following these instruc operation
tions will allow you to avoid hazards, reduce repair costs and downtime and increase
the reliability and service life of the Geared variable speed coupling.
Read this Instruction Manual carefully, to become familiar with the proper handling Reading the
and operation. Instruction Manual
The Instruction Manual must always be available at the installation site of the Geared Installation site
variable speed coupling.
This Instruction Manual is protected by copyright laws. Without prior written approval Copyright
from Voith Turbo GmbH & Co. KG, it cannot be duplicated in whole or in part, distri
buted or passed on to third parties for competitive purposes.
The contents of this Instruction Manual are intended for various target groups. Definition of target
The knowledge level that each target group must have is defined here. groups
All target groups must have read this Instruction Manual and have a good understan
ding of the contents.
Operating personnel must
• be 18 years old.
• have received training in the proper handling of the Geared variable speed cou
plingGeared variable speed coupling.
• know the country-specific accident prevention regulations.
Maintenance personnel must
• know the items on the Geared variable speed coupling that require maintenance.
• know the country-specific environmental protection regulations regarding disposal
of lubricants and cleaning materials.
Service personnel must
• have an in-depth school and vocational education.
• have been trained by Voith Turbo GmbH & Co. KG in the service activities for the
Geared variable speed coupling.
• have been instructed in the procedures to follow in the event of a malfunction.
VOITM General Information on the
Voith Turbo I Geared variable speed coupling I SEC S61ndonesia Pelabuhan I R 15 K 400
Instruction Manual
Our equipment is continually undergoing further development and improvement. Technical changes
The data contained in this edition corresponds with the latest technology.
We reserve the right to any changes in technical details differing from the information
and images in the Instruction Manual.
Besides those regulations for accident prevention stipulated in the Instruction Manual, Accident prevention
those in the country of use and the installation location, the recognized technical re rules
gulations for safety and proper work practices are to be observed.
Notes on using the Instruction Manual
Warnings regarding handling: Presentation of

safety-related infor
mation
1 2
Type of hazard ------,~
Consequences of the hazard -----,~
Countermeasure
_ _.a....-_ _j_ _ _ _ _ _ _ _......
~
.
Summary of safety information and additional notes at the beginning of each

chapter:
Type of hazard 0
Consequences of the hazard ~
Countermeasures to take ~
1. Safety symbol
2. Signal word - Danger level
3. Type and source of the danger
4. Possible consequences
5. Measures to take to reduce the hazard
6. Safety symbol
II
VOITM General Information on the
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I A 15 K 400 Instruction Manual
Notes:
Points to a location with important information regarding use and/or

procedures to follow. Non-observance/non-compliance can cause
malfunctions.
Texts are identified in the following manner regarding their function: Identification of
types of text
Identifica
Type of text Function
tion/marking:
Instruction regarding an ac 1., 2., etc. means that an action is required
tion
List • identifies/marks individual items in a

1. level list
List identifies/marks subitems in a list

2. level
Cross reference points to other chapters or segments

of text
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VOITH General information on the
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400
Instruction Manual
Page layout:
(DJ-+-- 3.4 Lubrioation
3.4.1 SelNubrleation
01-----:- Se_aririg~ ard ge~~'s. {>; t\'-e G<:,Qf,;C \I::;'1.].blt;- Gpe<;-d cou;:Air.g r-ecUI'e ~u~'·'c')".r'l-; 'JiI!or
:Job-ting up. duri~9 opo!rc:tnn ,and ·,·,'h~n ::hJttiog GOV,,';I
Du'-i,~g cpoeor~tion. th~ n".:ll>: oil p-;.;rn~' d"l,.,'er;:; 0,1 fr·';lF.' t>-,e oj re~_et\'o,r :nlc
c,;.;:.>it At ~tt.fLp ~rd ot,h...::.<iC'o'T:, 1hz .).~,t!,.a~~( iui)e oj, O:..;!l',P .suDpl~e;; t~;-e ci: fe·,
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l:..i:!-r,cano:m T!-;e c," flo'/>$ through
t1'B che;ck ;,,':]I-.)e

• t~,e IUbn-::"_oting oi-: ::;::oele~ and
.. ttc€ du~-I~). or; filte'"
Th.... ;ube c-~ flew 'ate fer ~"e b-t::,r n?c ~"d ~rc ic &.et \':!'r mo:!~,: ';~ (.c-·,,~ du]~ cr Lube Qil ft,y...· ra\e
c:,r;; c.e ope",ing~ ~n the iu~,e c-': n-:.==Ie<;, E~<:i!':;;~ oii fl·,,,,,,,,,, \!'*:> !he ,>f.)rb"'9 :)" ;:i'c,_,t-.r.a
th£' "'~nc~ ...a1;;~
Th-:- lube o~ flJ:1'4 rate 120:", :''00 o,+e.;d ~"'\ :flcir~tly bV !'':If.'ur:,,c of the- Lbe oil Pl<::s.~_l1r-e
Th-e- iUrY4;ting .1,1 pre::;~!...l'e i~ ~ at 1M ~ou""nce v.:t1'o'e anc :3 I'OCOrnroted 'Nhh Lube oil pressure
\7.i't·ei:~U'-.e rr-e;;'."'.;T,ns: d"'vice~ tpf.eGS~1-e g.:wg,"" Ir~C1C,n'ltter. G>N;tcN
Lube J)i!
temperntur--e
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Th.,.. blkl>N;ng ~r,tb!litio;.::;. <e:>;et contr<.:tl
Mi~ed -c~~.trc<i (vn the 0- ::;.,;::Ie';

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1. Type of equipment
2. Code
3. Coupling size
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Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 Contents
Contents
1 Technical data.......................................................1
1.1 Machine data ......................................................................1
1.2 Operating data .....................................................................4
1.2.1 The Geared variable speed coupling ................................................... .4
1.2.2 Heat exchanger ....................................................................7
2 Safety information .. ............................................... ..8
2.1 Basic principles underlying the design of the equipment. ....................................8
2.2 Proper use of the equipment ..........................................................8
2.3 Improper use of the equipment ........................................................8
2.4 General safety information ............................................................9
2.4.1 Safety symbol .....................................................................9
2.4.2 Hazard classification ................................................................9
2.4.3 Maintaining and replacing safety symbols ...............................................10
2.4.4 Personal safety ...................................................................10
2.5 General safety information ...........................................................11
2.6 Organizational measures ............................................................12
2.7 Personnel selection and qualification, basic obligations ....................................13
2.8 Obligations of the operator ..........................................................13
2.8.1 Protection systems ................................................................14
2.8.2 Designating and instructing responsible individuals .......................................14
2.8.3 Obligations regarding information .....................................................14
2.9 Operation of the system .............................................................15
2.10 Working on the system .............................................................15
2.11 Electrical/electronic equipment .......................................................17
u, 2.12 Special types of hazards ............................................................18
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Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400
Contents
3 Design and principle of operation .................................... .23
3.1 Design ..........................................................................23
3.2 Power transmission ................................................................25
3.3 Speed control ....................................................................27
3.4 Lubrication .......................................................................30
3.4.1 Self-lubrication ....................................................................30
3.5 Lubrication of external equipment .....................................................31
4 Transport and storage .. I •••••• I •• I •••••••••••••••• I ••••••••••••••• I .32
4.1 Safety information .................................................................32
4.2 As-delivered condition ..............................................................33
4.2.1 State of assembly and test run .......................................................33
4.2.2 Preservation/corrosion prevention and packing ...........................................34
4.3 Storage and preservation ...........................................................34
4.4 Unpacking, transportation ...........................................................35
4.4.1 Lifting with swivels .................................................................38
4.5 Preservation specification .......................................................... .41
4.5.1 Internal corrosion-inhibiting oils ...................................................... .43
4.5.2 To be ensured at the installation site: ................................................. .44
5 Configuration ............ I •••••••• I I •• I ••••••••• I •• I ••••••••••• I ••• 45
5.2 Tools and other aids ...............................................................47
5.2.1 How to seal the keyway ............................................................ .47
5.3 Checking the concrete foundation .....................................................48
5.4 How to set the steel plates around the anchor holes ...................................... .48
5.5 Mounting the connecting couplings ................................................... .49
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5.9 Machine alignment. ................................................................55
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VOITM
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 Contents
5.11 Plumbing the machine to the heat exchanger ............................................63
5.11.1 Installing the heat exchanger. ........................................................63
5.11.2 Horizontal heat exchangers ..........................................................64
5.11.3 Vertical heat exchangers ............................................................65
5.11.4 Installing the oil lines ...............................................................66
5.11.5 Installing the vent lines .............................................................67
5.11.6 Pickling of oil lines .................................................................68
5.12 Connecting electrical instruments .....................................................71
5.13 Attaching guards ..................................................................72
5.13.1 Attaching guarding to prevent contact ..................................................72
5.13.2 Attaching sound-absorbing covers ....................................................73
5.14 Orifice holes for lube 011 supply to external units ..........................................75
6 Commissioning.....................................................76
6.2 Fill the working oil .................................................................77
6.3 Flushing the coupling ...............................................................78
6.4 Trial run .........................................................................79
6.4.1 Preparing for the trial run ............................................................79
6.4.2 Conducting the trial run .............................................................80
6.5 Adjusting the lube oil and control oil pressures ...........................................82
6.6 Adjusting the working oil flow rate .....................................................84
6.7 Operating fluids ...................................................................87
7 Operation..........................................................88
7.2 Starting up and shutting down the equipment ............................................90
7.3 Operating the equipment ............................................................91
7.3.1 Monitoring the equipment ...........................................................91
iii 7.3.2 Controlling the speed ...............................................................94
~ 7.3.3 Changing over the duplex oil filter .....................................................94
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...c;; 7.7 Measures to take during stop periods ..................................................98
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VOITN
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 Contents
8 Maintenance ......................................................100
8.1 Safety information ................................................................100
8.2 Maintenance and repair ............................................................102
8.2.1 Maintenance measures and intervals .................................................102
8.2.2 Service/repair measures and intervals ................................................103
8.3 Cross references .................................................................104
8.4 Cleaning the duplex oil filter.........................................................105
8.5 Test criteria and notes for evaluating working oils ........................................108
8.6 Replacing the fusible plugs .........................................................110
9 Troubleshooting ..... ............................................ ..111
9.1 Startup .........................................................................111
9.2 Output speed ....................................................................112
9.3 Pressures.......................................................................113
9.4 Temperatures ...................................................................114
9.5 Smooth operation ................................................................116
9.6 Cross references .................................................................117
10 Introduction to general overhaul .....................................118
10.1 Safety information ................................................................118
10.2 Tools and auxiliary means ..........................................................120
10.3 Preparations ....................................................................121
10.4 List of components ................................................................122
11 Drawings, schematics, diagrams . .................................. ..123
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12 Parts list ............................................. I I •••••••••• 124
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Voith Turbo I Geared variable speed coupling I SEC S61ndonesia Pelabuhan I R 15 K 400 Contents
14 Attaching parts ....................................................127
14.1 Resistance thermometer ...........................................................127
14.1.1 Resistance thermometer ...........................................................127
14.1.2 Connection head .................................................................127
14.2 Pressure gauge with shutoff valve ....................................................128
14.2.1 Pressure gauge ..................................................................128
14.2.2 Shutoff valve with test connection ....................................................128
14.2.3 Primary shutoff valve ..............................................................128
14.3 Pressure switch with shutoff valve ....................................................129
14.3.1 Pressure switch ..................................................................129
14.3.2 Shutoff valve with test connection ....................................................129
14.4 Differential pressure indicator with Switch ..............................................130
14.4.1 Differential pressure indicator .......................................................130
14.5 Oil level indicator .................................................................131
14.6 Voith electro-hydraulic position control unit .............................................132
14.7 Duplex filter with filter element. ......................................................133
14.7.1 Duplex filter .....................................................................133
14.7.2 Filter element ....................................................................133
14.8 Auxiliary lube oil pump .............................................................134
14.8.1 Gear pump ......................................................................134
14.8.2 Connecting coupling ..............................................................134
14.8.3 Lantern (bell housing) .............................................................134
14.9 Three-phase motor for auxiliary lube oil pump ..........................................135
14.10 Heat exchanger ..................................................................136
14.10.1 Working oil heat exchanger: ........................................................136
14.10.2 Lube oil heat exchanger: ...........................................................136
14.11 Shutoff valve - Oil reservoir .........................................................137
14.12 Vent filter - Geared variable speed coupling ............................................138
14.13 Measuring connection - Geared variable speed coupling ..................................139
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Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M 1 Technical data
1 Technical data
Geared variable speed coupling R 15 K 400 M
Code SEC S6 Indonesia Pelabuhan
Order number 38001567
Serial No. 8204536 to 8204538
1.1 Machine data
Geared variable
The Geared variable speed coupling as boiler feed pump drive speed coupling
Direction of rotation viewed in direction of power flow:
Input shaft ccw
Hydr. circuit CW
• Output shaft CW
Power requirement of the driven machine Pa 2685 kW
Motor speed ne 1490 rpm
Gear ratio U 1 = Z2/Z 1 147 I 41
Primary speed n1 5342 rpm
Full-load slip s 2.85 %
Max. output speed na 5190 rpm
Regulation range 4:1 downwards
Capacity of oil reservoir 1000 I
Required oil viscosity ISO VG 32
Weight
• Total (without oil) 6300 kg
input shaft with gear 673 kg
Primary-side components of the coupling runner with 151 kg
gear pinion
Secondary-side components of the coupling runner 42 kg
Noise emission: 1
• Surface sound pressure level LpA ~94 dB
1. Measurement as stipulated in EN ISO 3744
Values obtained from measurements made on identical equipment
VOITN
Attaching parts
Pump Insert
Pumps Working oil pump and lube 011 pump incorpo

rated into pump insert
Working oil pump type KP 144
Lube oil pump type MZP 450
Drive Jointly by the input shaft of the

Auxiliary lube oil pump
Type R69/315 FL-Z-W-R
Drive Electric motor
Motor for auxiliary lube 011 pump
Type ASS
Design type 1M / V1 with protective roof
Degree of protection IP 55
Duplex oil filter
Type DU 631.30801.25G.30.E.P.FS.9.
Grade of filtration 25 IJm
Filter element Element, may be cleaned
Attainable oil cleanliness grade (to DIN ISO) 18/ 15 1
1. Oil cleanliness grade as defined in ISO 4406
Voith electro-hydraulic positioning control
Type VEHS
Design Control solenoid

• 4/3-way valve
Double-acting positioning cylinder
Position pickup with position transmitter
2
VOITN
Connecting couplings
Input side not supplied by Voith-Crailsheim
Output side not supplied by Voith-Crailsheim
011 level Indicator/switch

Indicator - type 25270/WEKA
Design Magnetic flap indicator
Switch - type 20000714/5
Design Magnetic switch
Heat exchanger
Working oil cooler type not supplied by Voith-Crailsheim
Lube oil cooler type not supplied by Voith-Crailsheim
Instruments
See Chapter 14 "Attaching parts" in this documentation
-+ For detailed documentation regarding the components mentioned, see Chapter 14

"Attaching parts" in this documentation.
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1.2 Operating data
1.2.1 The Geared variable speed coupling
Temperatures
Bearing temperatures Operating range <90°C

Alarm at 90°C
Shutdown at 95 °C
Working oil temperature

Operating range > 60 < 110°C
upstream of heat exchanger
Alarm at 110 °c
Shutdown at 130°C

Operating range >35 < 75°C
downstream of cooler
Alarm at 1 75°C
Shutdown at 1 85°C
Lube oil temperature

Operating range > 45 < 65 °c
upstream of cooler
Alarm at 1 65°C
Shutdown at 1 70°C

Operating range > 35 < 55 °c
downstream of heat exchanger
Alarm at 55°C
Shutdown at 60 °c
Oil temperature
Start enabled 5°C
in oil reservoir
Operating range 1 >45<65°C
Alarm at 1 70°C
Shutdown at 1 75°C
1. Signal, only with appropriate instrumentation
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Pressures
Working oil pump pressure

1.5 to 2.5 bar
Test connection M1 (see assembly plan)
Working oil pressure upstream of oil circulation valve 1

1.3 to 2.3 bar
Working oil pressure downstream of the scoop tube

max. 3.0 bar
Lube oil pressure Operating range 2 2.5 + 1 bar

Actuation of the driving machine at t 1.7 bar
Shutdown of the aux. lube oil pump at 3 t 2.2 bar
Alarm - aux. lube oil pump ON at J. 1.5 bar
Shutdown of driving machine at J. 0.8 bar
Lube oil pressure for external units 2.0 bar
Differential pressure across duplex Switch and clean filter at > 0.8 bar
oil filter
Control oil pressure Operating range 3.0 to 4.0 bar

Test connection M4 Setting 3.5 bar
(see assembly plan)
1. Factory setting: approx. 1.8 bar

2. In the case of overly high bearing temperatures but adequate cooling of the lube oil, an increase
up to 4 bar is possible. Factory selting: approx. 2.5 bar
3. Further switching by means of a time-delay relay after 3 minutes
Oil quantities
Working oil flow rate max. 452 I/min
Lube oil flow rate for 2101/min

Lube oil flow rate

to external units:
Total
1171/min
Boiler feed pump
851/min
Booster pump
-I/min
Motor
321/min
Connecting coupling
-I/min
5
VOITM
Vibrations - housing
Housing Alarm at >5.6 mm/s1

(radial) Shutdown at > 8 mm/s1
Housing Alarm at > 8 mm/s1

(axial) Shutdown at > 11.5 mm/s1
Vibrations - shafts
Input shaft Alarm at Spp> 117IJm 1

(radial - X) Shutdown at Spp> 170 IJm1
Input shaft Alarm at Spp> 117IJm1

(radial- Y) Shutdown at Spp> 170 IJm1
Output shaft Alarm at Spp> 85IJm1

(radial- X) Shutdown at Spp> 123IJm1
Output shaft Alarm at Spp> 85IJm 1

(radial- Y) Shutdown at Spp> 123IJm1
These limits can be maintained only so long as there is no foundation resonance within the
speed range.
1. Signal, only with appropriate instrumentation or manually on site.
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VOITM
1.2.2 Heat exchanger
Design data
Working 011 heat exchanger 1 Shell chamber Tube chamber
"not supplied by Voith-Crailsheim" (011) (water)
Heat to be dissipated 505 kW
Medium Oil Water
Volumes _I _I
Nominal flow rate V nom
Minimum flow rate as the result of corrosion Vmin
Inlet temperature 95°C °C
Outlet temperature 56°C °C
Permissible operating temperature °C °C
Permissible pressure loss 0.8 bar
Permissible operating pressure (gauge) bar bar
Test pressure (gauge) bar bar
1. Have heat exchanger supplier complete design data
Lube 011 heat exchanger 1 Shell chamber Tube chamber

"not supplied by Voith-Crailsheim" (oil) (water)
Heat to be dissipated 94kW
Medium Oil Water
Volumes
Nominal flow rate V nom
Minimum flow rate as the result of corrosion Vmin
Inlet temperature 60°C °C
Outlet temperature 49°C °C
Permissible operating temperature °C °C
Permissible pressure loss 1.0 bar
Permissible operating pressure (gauge) bar bar
Test pressure (gauge) bar bar
1. Have heat exchanger supplier complete design data
7
VOITH
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 M 2 Safety Information
2 Safety information
2.1 Basic principles underlying the design of the equipment
The Geared variable speed coupling has been designed and manufactured using the Basic principle
latest technology and in accordance with accepted safety principles. Nevertheless, its
use can result in danger to life and limb of the user or damage to the equipment itself
and other property.
The Geared variable speed coupling is to be operated only if it is in proper working Use of the
condition and only for the designated use, in a safety-conscious manner that complies equipment
with the Instruction Manual, including knowledge of the associated dangers! Immedi
ately correct any situations that adversely affect safety.
2.2 Proper use of the equipment
The Geared variable speed coupling is used to transmit power in a wear-free manner Use of the
from a prime mover (driving machine) to a power consumer (driven machine). Use the equipment
equipment only for the designated purpose.
Complying with designated use also means satisfying the manufacturer's require
ments regarding operating conditions, maintenance and repair.
Use of the equipment for any other purpose is considered improper use. The manuf
acturer assumes no liability for damage arising from improper use; the risk associated
with improper use is borne by the user.
2.3 Improper use of the equipment
The permissible power that can be transmitted by the coupling in a stationary installa
tion for a given input speed, power input, direction of rotation, oil flow rate in external
machines, and 011 reservoir content is specified in this Instructin Manual. Any other
use beyond that described herein, e.g. for higher power levels, higher speeds, pos
sibly lower speeds, with other operating fluids, under operating conditions that have
not been agreed upon or involving physical modifications is considered improper use.
8
VOITM
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M 2 Safety information
2.4 General safety information
2.4.1 Safety symbol
The safety symbol is used to alert you to possible risk of personal injury. Heed all in
structions following this symbol in order to avoid possible injury or death.
2.4.2 Hazard classification
Hazard classification applicable to warnings about procedures (see following examp

les), summarized safety information and additional instructions at the beginning of
each chapter.
Indicates an immediate, potentially dangerous situation which - if the safety regulati- Danger
ons are not observed - could result in death or serious bodily injury.
A IIIIER
Indicates a potentially dangerous situation which - if the safety regulations are not ob- Warning
served - could result in death or serious bodily injury.
Indicates a potentially dangerous situation which - if the safety regulations are not ob- Caution
~ served - could result in damage to equipment or slight to moderate bodily injury.
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A" CAUTION
9
VOITN
Indicates a potentially dangerous situation which - if the safety regulations are not ob- Caution - with safety
served - could result in damage to equipment. symbol
2.4.3 Maintaining and replacing safety symbols
The safety of the operator must always take priority.
• Replace all damaged or lost safety symbols.
• Use a mild cleaning agent and water to clean the safety symbol.
Do not use any cleaning agents that contain solvents.
2.4.4 Personal safety
The Instruction Manual and safety symbols described therein must be read and un
derstood by all individuals who work on or with the Geared variable speed coupling.
10
VOITN
2.5 General safety information
• Compliance with the manufacturer's Instruction Manual is mandatory for operation,
maintenance, repair, assembly and transport.
• The operator must provide additional specific safety instructions that reflect the lo
cal operating conditions, if deemed to be necessary.
• This Instruction Manual and the safety information contained therein must be
stored in a safe location.
• This Instruction Manual and the safety information contained therein must be kept
in their entirety and in always legible condition.
• Prior to starting any work, familiarize yourself with first-aid and rescue procedures Prior to starting any
(how to contact a doctor, the fire department or rescue services in an emergency). work
• Familiarize yourself with the location and operation of fire extinguishers as well as
the location of fire alarm boxes and fire fighting equipment.
• Never disable safety devices or remove them. While working
• Wear protective work clothing while working. Remove rings, shawls and open jack
ets. For certain work, you must wear safety goggles, safety shoes, a safety helmet,
protective gloves, a reflecting vest, ear protection etc.
• Refrain from any behavior that adversely affects safety.
• Operate the Geared variable speed coupling only when it is in safe and functional
condition.
• Never operate the equipment with defective monitoring devices.
• Ensure compliance with applicable environmental protection regulations whenever Environmental

working on or with the Geared variable speed coupling. protection regula
tions
• Take precautions especially during installation, repair and maintenance work that
substances hazardous to the environment such as grease and oil or solvent-con
taining cleaning liquids do not get into the soil and sewage system. These sub
stances must be stored, transported, collected and disposed of in suitable con
tainers.
• If the above-mentioned liquids are seeping into the soli, you must stop their escape
immediately and treat the area with a liquid-binding absorbent. It may be neces
sary to remove the soil.
"=, • Dispose of the absorbent and any soil removed properly and in compliance with
!, applicable environmental protection regulations.
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VOITM
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M 2 Safety Information
2.6 Organizational measures
This Instruction Manual contains important information regarding proper handling of instruction Manual
the Geared variable speed coupling. Before installing the equipment and especially
before commissioning the entire system, read the Instruction Manual carefully and
ensure that it is understood.
Store the Instruction Manual such that it is available to the operating personnel at all
times.
In addition to the Instruction Manual: ensure that regulations regarding accident pre Accident prevention I
vention and environmental protection are accessible and observed. environmental
protection
In the event of physical modifications: Physical modifica

tions
Danger arising from physical modification
Physical modifications of the Geared variable speed

coupling can result in personal injury and damage to
equipment.
Modifications, additions or changes to the Geared

variable speed coupling are permitted only after
receiving approval of Voith Turbo GmbH & Co. KG,
Crailsheim.
NOTE
Additional components that are not supplied by Voith Turbo GmbH & Co. KG
must be inspected for internal or external damage and contamination (possibly
by silicone-containing sealing compunds) prior to being installed or attached.
Ensure proper operation.
12
VOITH
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 M 2 Safety Information
2.7 Personnel selection and qualification, basic obligations
• Only properly trained and instructed personnel must be allowed to work on the Ge- Trained personnel
ared variable speed coupling. These personnel must be trained, instructed and au
thorized to
- Operate and maintain the equipment properly and in a manner that ensures
compliance with safety standards
- Dispose of liquids and their associated components, e.g. filters, oil filter car
tridges and oil, properly
- Service and use safety devices in a manner that ensures compliance with
safety standards
- Provide first aid and prevent accidents.
• Untrained, uninstructed and unschooled personnel as well as personnel currently Untrained personnel
receiving general training and instruction must not be allowed to perform any ac
tions on the equipment unless they are under the continuous supervision of an ex
perienced individual.
2.8 Obligations of the operator
A Geared variable speed coupling that is not in proper operating condition can cause
personal injury and damage to equipment.
The operator is obligated to operate the Geared variable speed coupling only if it is in
proper operating condition.
Hazardous areas between the Geared variable speed coupling and customer's equip
ment must be protected by the operator.
The Geared variable speed coupling generates heat that raises the temperature in the
immediate surroundings and may have an adverse affect on personnel. The operator
is obligated to always provide adequate ventilation.
When work is being performed on the equipment, the operator must provide adequate
illumination.
13
VOITM
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 M 2 Safety information
2.8.1 Protection systems
Protection systems, interlocks and couplings on the system are to be inspected for
safe operation on a regular basis by a qualified specialist.
Areas on the housing of the coupling, working oil lines and the working oil cooler re
ach surface temperatures> 60°C. Guarding to prevent contact with these areas is not
supplied with the coupling, since conditions at the subsequent installation site are not
known, and complete guarding to prevent contact can be cumbersome and severely
restrict access required for maintenance.
We recommend that, by taking suitable measures at the installation site, e.g. marking
aisles, installing warning signs and instructing personnel access be restricted to
areas needed during normal operation. These include the instrument gauge panel
and the oil filters (for the required exchange of filter elements).
If protective guarding is nevertheless required, this will require an evaluation of condi

tions on-site. In such a case, Voith Turbo still recommends limiting the guarding to only
essential measures, e.g. areas "within arm's length of aisles used during normal ope
ration". Voith Turbo can offer this as an option after clarification of details.
2.8.2 Designating and instructing responsible individuals
Assign only personnel with proper training or instruction, clearly designate the re
sponsibilities for operation, adjustment, maintenance, repairs.
Regularly check that personnel maintain safety-conscious work habits in compliance Safety-conscious
with the Instruction Manual and are aware of the dangers involved. work
2.8.3 Obligations regarding information
The personnel responsible for performing any work on the system must, prior to star Reading the
ting such work, read the Instruction Manual, and the Safety information chapter in Instruction Manual
particular. Reading while performing the work is too late. This applies especially to
personnel who work on the system only occasionally, e. g. to perform maintenance on
the system.
The Instruction Manual must always be kept in a readily accessible location at the in
stallation site!
14
VOITM
2.9 Operation of the system
Heed all safety instructions and hazard notices on the system! Ensure that all safety Information on the
instructions and hazard notices on the system are present and in legible condition! system
Supplement the Instruction Manual with information about monitoring and reporting Special aspects of
obligations in order to account for special aspects of operation, e. g. with regard to or operation
ganization of work, work procedures, assigned personnel.
The personnel are not allowed to have long, loose hair, or wear loose clothing or je Risk of injury
welry, including rings. These pose the risk of injury, e. g. by becoming caught in ma arising from
chinery. clothing and the like
Use personal protective equipment whenever necessary or required by regulations! Protective

equipment
2.10 Working on the system
Observe the adjustment, maintenance and inspection intervals, including replace Maintenance
ment of parts, specified in the Instruction Manual! These activities may only be perfor
med by qualified individuals.
Inform personnel before starting to perform any special or maintenance work! Desig
nate supervisors!
Comply with all procedures for switching equipment on and off specified in the Instruc Switching on and off
tion Manual as well as instructions regarding servicing of equipment when performing
any work that involves operation or adjustment of the system and its safety devices or
inspection, maintenance or repair!
Safeguard as large a maintenance area as necessary!
If the system has been switched off completely for maintenance and repair work, it Securing against
must be secured against being switched on again unexpectedly. being switched on
Spare parts must meet the technical specifications of the manufacturer. This is always Spare parts
assured by purchasing genuine Voith replacement parts.
Individual parts and larger assemblies are to be carefully fastened and secured to lif Lifting appliances
ting gear when being exchanged so that no danger is posed. Use only suitable lifting
appliances and accessories that are in good condition and have the necessary load
carrying capacity! Do not work or stop under suspended loads!
When performing assembly work above body height, use the provided or other safety Work performed
ascent aids and work platforms. Do not use parts of the system as ascent aids! above body height
Before starting maintenance/repair work, clean the system, especially connections Connections and
and threaded fittings, of oil, lubricants or similar substances! Do not use any aggres threaded fittings
sive cleaning agents! Use lint-free cleaning rags!
15
VOITM
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M 2 Safety Information
Always tighten bolted connections when performing maintenance or servicing the Bolted connections
equipment!
If disassembly of safety devices is required when performing maintenance and re Completion of
pairs, these safety devices are to be reassembled and checked for proper operation maintenance and
immediately after the completion of the maintenance and repair work. service work
Ensure that all operating fluids and replaced parts are disposed of safety and in an en
vironmentally responsible manner!
In addition to the Instruction Manual, ensure that generally applicable as well as any
specific regulations regarding accident prevention and environmental protection are
observed and pointed out!
In the event of any system modifications that affect safety or any changes in the ope
ration of the system, shut the system down immediately and notify the responsible
party/individuals of the malfunction!
Observe the specified deadlines for recurring maintenance/service work! Always Maintenance/service
ensure that maintenance instructions and intervals are observed.
Keep access paths to areas needed for service work free of obstructions.
Servicing of the equipment requires tools that are appropriate for the work to be per
formed.
The system must be disassembled only by qualified personnel who perform their work Relocating the
in compliance with local safety regulations. equipment
Suitably pack components that are subject to breakage, drain fluids where necessary.
Protect the environment. Comply with local regulations. Disposal
Prior to disassembly for salvage purposes or scrapping, completely remove any oil or
other substances that pose a danger to water.
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VOITH
2.11 Electrical/electronic equipment
Danger to life
Dangerous electric currents and voltages on the

Geared variable speed coupling can injure or kill
individuals.
Only a qualified electrician who is knowledgeable

about rules that apply to electronic equipment is
allowed to perform work involving the electrical
equipment on the Geared variable speed coupling.
Use only new fuses rated for the specified current! Shut down the system immediately Electrical energy
in the event of problems with the electricity supply!
Work on electrical equipment or machinery must be performed only by a qualified

electrician or by trained individuals under the direction and supervision of a qualified
electrician who is knowledgeable about the rules that apply to electronic equipment.
System components on which inspection, maintenance or repair work is being perfor

med must - if so specified - be switched off and secured against being switched on
again. Check disconnected components to ensure the absence of electrical voltage,
then ground and short circuit them; isolate adjacent components that are still connec
ted to electricity!
The electrical equipment must be inspected/checked on a regular basis. Deficiencies

such as loose wires or charred cables must be replaced immediately.
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VOITM
2.12 Special types of hazards
When handling oil and grease, observe the safety regulations that apply to the pro Oil, grease and
duct! aerosols
Exercise caution when handling hot operating fluids and similar substances (risk of
burns and scalding)!
Escaping aerosols can be absorbed into the body via the skin, eyes and lungs, caus
ing irritations or injuries. The operator is obligated to always provide adequate venti
lation.
2.13 Interface to machinery from others
The danger area that arises at an interface to machinery from others must be protec
ted by the operator.
2.14 Prohibition against arbitrary modifications
Do not make any alterations, modifications or add any attachments to the system that Modifications
could affect safety before receiving approval from Voith Turbo GmbH & Co.KG Crails
heim!
18
VOITM
Voith Turbo I Geared variable speed coupling I SEC 56 Indonesia Pelabuhan I R 15 K 400 M 2 Safety information
2.15 Cleaning the Geared variable speed coupling
Risk of Injury
Rotating parts on the system can cause injury.
Shut down the system when it is necessary to clean

these parts.
2.15.1 Cleaning agents
Risk of injury
Flammable solvents can burst into flame and cause
injury.
Use only approved cleaning agents.
2.15.2 For normal dirt
• Use commercially available, non-flammable solvents.
• If solvent vapors can be inhaled, breathing protection must be worn.
• Do not allow solvents to drain into the sewage system.
• Heed the identifying information and instructions on the containers and the pack
aging of the cleaning agent.
19
VOITH
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 M 2 Safety information
2.16 Individual phases of operation
Equipment damage
The Geared variable speed coupling is delivered

without any oil in it. Operation without oil will damage
the equipment within a few seconds.
Prior to startup, fill the Geared variable speed

coupling with the working oil!
Proper operation of the Geared variable speed coupling requires that the
instruments be functioning correctly.
• The Geared variable speed coupling can be damaged if Commissioning
- it is started without working oil,

- the heat exchanger and the lines to the heat exchanger have not been flushed
prior to commissioning,
- a working oil not approved by Voith is used,
- the equipment was filled with contaminated working oil,
- the heat exchanger does not have adequate cooling capacity.
• The Geared variable speed coupling can also be damaged
- if the driving machine is is not rotating in the correct direction or

if the components that are supplied with lubricating oil from the Geared variable
speed coupling are sealed with silicone-containing gaskets.
20
VOITM
• Perform specified maintenance at the times indicated! Maintenance
• Immediately repair or exchange components that are not in perfect operating con
dition. Use only genuine Voith replacement parts!
The working oil in the Geared variable speed coupling may be under pressure. Prior
to performing any maintenance or repair work, disconnect the equipment from the
electricity (observe local regulations!)
The housing, oil lines, connecting couplings and working oil may be very hot - in ex
treme cases, up to 130°C. Contact can cause burns on the skin.
The Geared variable speed coupling must be allowed to cool prior to maintenance or
repair work!
When steam cleaning or using a stream of water under high pressure, dirt may be Cleaning
forced into the equipment.
Protect shaft seals (labyrinth seals) and breather filters on the Geared variable speed
coupling, so that the stream of water or steam does not strike them directly.
Note the following when disposing of used oil: Disposal of used oil
Environmental damage
Used oil that escapes into the sailor sewage system

can cause serious damage to the environment.
Dispose of used oil in a proper manner that complies

with national statutory regulations.
21
YOITM
Voith Turbo I Geared variable speed coupling I SEC S61ndonesia Pelabuhan I R 15 K 400 M 2 Safety Information
2.17 Warranty
The conditions specified in the general terms of delivery of Voith Turbo GmbH & Co.
KG Crailsheim apply with respect to warranty claims. Warranty claims will be rejected
if they are attributable to one or several of the following causes:
• Improper transportation, storage, setup, commissioning or operation of the Geared

variable speed coupling,
• If service, repairs or modifications that affect operation were not performed by

Voith technicians or personnel trained by Voith.
• Failure to comply with the instructions regarding occupational safety and product
safety contained in the Instruction Manual,
• Filling the Geared variable speed coupling with contaminated oil, with different oil
grades or with a grade that does not appear on the Voith-authorized list or is not
approved by Voith Turbo GmbH & Co. KG Crailsheim.
NOTE
During the warranty period, repairs to the Geared variable speed coupling may
be performed only with the approval of Voith Turbo GmbH & Co. KG Crailsheim.
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VOITN 3 Design and principle of
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M operation
3 Design and principle of operation
3.1 Design
Illustration 3-1: The design of the Geared variable speed coupling
Housing with oil reservoir 12 Radial bearing 23 Duplex oil filter
2 Input shaft 13 Mechanical working oil pump 24 Heat exchanger (lube oil)
3 Gear unit with gears and 14 Mechanical lube oil pump 25 Heat exchanger (working oil)
gear pinion shaft
15 Auxiliary lube oil pump with 26 Instruments / measuring connection
4 Primary shaft (gear pinion shaft) electric motor
27 Check valve
5 Primary wheel 16 Scoop tube
28 Adjustable orifice (control oil)
6 Secondary shaft 17 VEHS position control unit
7 Secondary wheel 18 Positioning cylinder (double acting)
8 Shell 19 Position sensor (scoop tube)

9 Working chamber 20 Oil circulation valve
10 Scoop chamber 21 Pressure relief valve (working oil)

11 Thrust bearing 22 Pressure relief valve
Control and lube oil
23
The Geared variable speed coupling consists of assemblies. These assemblies are Modules
called modules. The joints are standardized.
The mechanical gearing and the coupling are combined in a two-piece sealed hou Housing
sing. The oil reservoir is flange-mounted at the bottom of the housing.
The coupling consists of the Coupling
• gear pinion shaft (primary shaft) and primary wheel,

• secondary shaft and secondary wheel,
• shell (flange-mounted to primary wheel, encloses the secondary wheel) as well as
the
• scoop tube housing with scoop tube control.
The primary shaft and primary wheel are permanently attached to one another, the
same is true of the secondary wheel and secondary shaft. The primary shaft is con
nected to the driving machine via the gear unit; the secondary shaft is connected to
the driven machine.
The primary wheel, secondary wheel and shell form the working circuit. The working
oil circulates within the working chamber. The shell and secondary wheel form the
scoop chamber.
The scoop tube housing is connected to the housing of the Geared variable speed
coupling. The secondary shaft is mounted in the scoop tube and bearing housings.
The gear unit consists of the input shaft with gearing and gear pinion shaft. Gear unit
All shafts are provided with plain bearings and lubricated. Bearings
The working oil and lube oil circuits are separate, but draw oil from the same oil reser- 011 pumps
voir. The oil is delivered by pumps.
The working oil pump and the lube oil pump are combined in the pump insert and are
both driven mechanically by the input shaft of the Geared variable speed coupling.
The electrically driven auxiliary lube oil pump supplies the system with lube oil during
startup, shutdown and in the event of a malfunction.
24
3.2 Power transmission
The Geared variable speed coupling transmits power in a wear-free manner from a
driving machine to a driven machine. The power is transmitted in the following way:
• by means of a connecting coupling between the driving machine and Geared vari
able speed coupling,
• by means of a step-up gear unit between the input shaft and primary shaft,
• hydrodynamically by means of the working oil between the primary wheel and the
secondary wheel,
• by means of a connecting coupling between the driving machine and Geared vari
able speed coupling,
The scoop tube control provide infinitely variable adjustment of the driven machine's
speed.
The power from the driving machine is transmitted to the primary wheel (function: Mechan Ical energy
pump) to the working oil; the working 011 is accelerated in the primary wheel, and the fluid flow energy
mechanical energy is converted into the energy of fluid flow. The secondary wheel
(function: turbine) picks up the flow energy and converts it into mechanical energy.
This energy is transmitted to the driven machine.
The torque at the primary wheel is identical to that at the secondary wheel.
Because of slip during power transmission, the speed of the secondary wheel (n2) is Slip
lower than that of the primary wheel (n1)'
[s = (1-n2/n1) x 100%]
The power loss resulting from the slip heats the working oil. To dissipate this heat, the
oil must be cooled.
Oil flows into the working circuit (working chamber) of the coupling via the oil circula Working 011 cooling
tion valve and, as a result of centrifugal force, forms a rotating ring of oil in the scoop circuit
chamber. The position of the scoop tube determines the height (thickness) of the oil
ring in the scoop chamber and thus the level of oil in the working chamber. The scoop
picks up the heated working oil in the scoop chamber and directs it to the working oil
cooler. There, it is cooled and then returned to the coupling through the oil circulation
valve. This completes the circuit.
If the amount of working oil in the coupling needs to be increased, the scoop is adjus
ted, and the working oil pump supplies additional oil from the oil reservoir to the cir
.~ cuit.
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loss incurred. Excess oil in the circuit is returned to the oil reservoir through the pres
Working oil flow rate
~ sure relief valve.

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YOITM 3 Design and principle of
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 M operation
The working oil temperature depends on the power loss (slip) and the working oil re Working 011 tempe
circulation rate. It is monitored by temperature sensors. rature
If cooling water consumption by the oil cooler is to be reduced, a temperature control Oil temperature
circuit for the working 011 based on reducing the flow of cooling water can be provided. control
However, the minimum flow rate for the cooling water must be maintained.
If as the result of a malfunction the oil temperature rises to 160 °cl, the fusible plugs Fusible plugs
in the coupling melt, and oil is diverted into the housing of the Geared variable speed
coupling. The coupling empties, and if the working oil pump does not supply any ad
ditional oil, the equipment comes to a stop.
Reasons for an increase in oil temperature could be:
• lack of cooling (cooler malfunction)
• overloading of the coupling
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VOITM 3 Design and principle of
3.3 Speed control
The Voith electro-hydraulic positioning control (VEHS) is a positioning control unit.
It consists of the: Design of the VEHS
• Control magnet (solenoid) with

- PIO positioner
- Magnetic force controller
• 4/3-way valve
- Control pin
The VEHS is connected to a:
• Double-acting hydraulic positioning cylinder, the piston of which is attached me

chanically to the scoop tube.
• Position pickup that determines the current position of the scoop tube.
Illustration 3-2:
Block diagram of the
VEHS pOSition control
unit
I
I B A Control magnet (so
I
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2 4/3-way valve
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3 Positioner
I 4 Magnetic force con
- -------------------~--- troller
5 Control pin
6 Master controller
7 Position pickup with
position transmitter
f t\'t'\\:~1
100 % 0% 8 Double-acting posi
L _ _ _ _ ...l
tioning cylinder
9 Scoop tube
The VEHS actuator is connected to a process controller (master controller) that gene Principle of
rates a setpoint signal of 4 - 20 mAo operation
6
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H
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VOITH 3 Design and principle of
Illustration 3-3:
Speed control by means
of the scoop tube
Scoop tube
2 Positioning cylinder
3 Chamber a
4 Chamber b
The speed of the driven machine is infinitely variable. This is accomplished by varying
the amount of oil in the coupling during operation with the aid of the adjustable scoop
tube:
• Scoop tube advanced as far as possible into the scoop chamber of the coupling
(0% position): minimum oil ring, minimum speed.
• Scoop tube retracted as far as possible out of the scoop chamber of the coupling
(100% position): maximum oil ring, maximum output speed.
The position of the scoop tube is determined by the VEHS (Voith electro-hydraulic po
sitioning control).
The scoop tube position is indicated
• by the mechanical indicator on the unit.

• by transmission of the current position signal to the positioner for use with a remote
display.
28
VOITH 3 Design and principle of
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 M operation
The process controller sends a setpoint signal, e.g. "max. output speed" (100%) to the Changing the output
VEHS positioning control unit. speed
The positioning control circuit compares the "current position signal" for the scoop
tube from the position pickup with the "setpoint signal" for the scoop tube from the pro
cess controller.
The resulting difference signals the magnetic force controller to change the position of
the control pin in the 4/3-way valve.
As a result of the changed position of the control pin, control oil flows into or out of the
double-acting positioning cylinder.
The control oil flows into chamber (a) of the scoop tube positioning cylinder and pus- Max. output speed
hes the piston with the attached scoop tube in the 100% direction (out of the scoop
chamber). The working oil pump adds oil to the working oil circuit.
The position change of the scoop tube positioning cylinder is sensed by the position
pickup, and fed back to the positioning control circuit continuously.
As the value of the difference decreases, the change in the position of the control pin
in the 4/3-way valve is reduced until the setpoint signal and current position signal
match.
For the opposite situation, the control oil flows into chamber (b) of the positioning cy- Min. output speed
linder and pushes the scoop tube in the 0% direction (into the scoop chamber). The
coupling empties. The working oil is returned to the oil reservoir via the pressure relief
valve.
The oil used to control the scoop tube hydraulically is diverted out of the lube oil circuit Control oil
upstream from the adjustable orifice.
The control oil pressure adjusted at the pressure relief valve and at the adjustable ori- Control oil pressure
fice. It depends on the lube oil pressure.
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3.4 Lubrication
3.4.1 Self-lubrication
The bearings and gears of the Geared variable speed coupling need lubricating oil be
fore and during operation.
During operation, the lube oil pump delivers oil from the oil reservoir into the lube oil Lube oil circuit
circuit. At startup and shutdown, the auxiliary lube oil pump supplies the oil for lubri
cation. The oil flows through
• the check valve,

• the pressure relief valve,
• the lube oil heat exchanger and
• the duplex oil filter
to the lubrication points after being cooled and filtered.
The lube oil flow rate for the bearings and gears is set by means of orifice plugs and Lube 011 flow rate
orifice openings in the lube oil nozzles. The excess oil flows back into the all reservoir
via the pressure relief valve.
The lube oil flow rate can be altered only indirectly by means of the lube oil pressure.
The lube oil pressure is set at the pressure relief valve and at the adjustable orifice, Lube 011 pressure
and is monitored by pressure measuring devices (pressure gauge, transmitter,
switch). Changes in the lube oil pressure affect the control oil pressure.
The lube oil temperature is monitored by temperature measuring devices. Lube 011 tempe
rature
Controlling the all temperature ensures good separation of air in the oil reservoir. The 011 temperature
following possibilities exist: control
• Mixed control (on the oil side)

- for larger cooling water temperature fluctuations in the lube oil cooler
- for stand-by units with a continuously operating auxiliary lube oil pump
- for cooling water temperatures below 15-20 °C
• Flow control (on the water side)

for smaller cooling water temperature fluctuations in the lube oil cooler How
ever, the minimum flow rate for the cooling water must be maintained.
30
3.5 Lubrication of external equipment
The oil for lubrication of the driving machine, the driven machine and/or the connec
ting couplings is drawn from the lube oil circuit of the Geared variable speed coupling
and returned to the oil reservoir of the Geared variable speed coupling.
The lube oil pressure and lube oil flow rate are set with the aid of the orifices plugs on Lube 011 pressure,
the flange connection of the Geared variable speed coupling and possibly with the aid lube oil flow rate
of the orifice plugs upstream of the respective lubrication points.
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Voith Turbo I Geared variable speed coupling I SEC 56 Indonesia Pelabuhan I R 15 K 400 M 4 Transport and storage
4 Transport and storage
4.1 Safety information
The following safety information applies to the entire chapter. It must be observed in
addition to the various specific instructions.
Hazard from loss of stability and danger arising from masses
As the result of inadequate packaging and securing, the coupling may have become
unstable and could shift unintentionally, causing serious injury.
Maintain a safe distance! Allow only knowledgeable personnel to handle transport!
Unqualified personnel could misjudge the weight of the coupling. This could (for in
stance, as the result of selecting unsuitable lifting equipment) allow the load to drop
on someone underneath, resulting in serious injury or death and/or cause severe da
mage to the coupling.
For weight data, see Chapter 1 "Technical data" and "Assembly Plan".
Allow only knowledgeable personnel to handle transport!
Hazard of crushing of upper and lower body limbs
Improper handling of the coupling, especially during transport by a crane, poses the
risk of crushing and serious injury.
Impact hazard
The suspended and swinging coupling could strike someone and cause serious injury.
Friction and abrasion hazard
The suspended and swinging coupling could rub against someone and cause friction
or abrasion wounds.
14 CAUTION I
Impact hazard during transport
While being transported, the coupling could strike a person or object, resulting in se
rious injury or damage. CAUTION 'I
Allow only knowledgeable personnel to handle transport!
32
VOITN
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M 4 Transport and storage
4.2 As-delivered condition
4.2.1 State of assembly and test run
The Geared variable speed coupling cannot be used on its own in the as-delivered
condition.
• The Geared variable speed coupling is fully assembled and ready for installation. State of assembly
• All internal piping for the working oil and lube oil are in place.
• All external piping connections are provided in the form of weld-neck flanges with
gaskets, and are sealed for protection during transport.
• If connecting couplings are being supplied by Voith or have been provided by the
customer, their hubs have been attached to the input and secondary shafts of the
• All instruments (gauges, switches etc.) are attached or installed in an instrument
panel. The panel is attached to the housing by means of vibration-absorbing
mounts.
• Electrical indicating instruments and switches are wired to a terminal strip in a
junction box.
• The instruments installed are identified.
• The VEHS positioning control unit has been mounted.
Prior to shipment, the Geared variable speed coupling underwent a trial run at the Vo- Test run
ith test facility.
The following items were checked:
• Attachments (such as duplex oil filter, electric motor etc.)

• Operation of the VEHS
• Absence of leaks in the piping
The following items measured:
• Losses during idling

• Oil and bearing temperatures
• Vibration 1
The following items were adjusted:
• Actuator
• Oil flow rates
• Oil pressures
• Operating points of the instruments installed
1. Evaluation on the basis of DIN ISO 3945, Items. 0-7, and as prescribed in VOl 2056, Machinery
group T
33
VOITM
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 M 4 Transport and storage
4.2.2 Preservation/corrosion prevention and packing
The Geared variable speed coupling and all attached components have been treated
(preserved) and packed in a manner that provides protection for 12 months.
4.3 Storage and preservation
The internal surfaces of the Geared variable speed coupling have a light film of oil in Corrosion
the as-delivered condition (either from the oil used during the trial run or from having protection for
had solvent-free corrosion-inhibiting oil sprayed on as corrosion protection 1). This film shipment within
of oil provides 12 months of protection within Europe, provided that the coupling is Europe
stored in a dry location.
For shipment overseas, the Geared variable speed coupling is additionally sealed in Corrosion
plastic film. Bags of desiccant inside the packaging absorb some of the humidity. protection for
Equipment packaged in this way can also be stored for 12 months in a dry location, shipment overseas
provided that the plastic film is not punctured or damaged.
-+ Section 4.5 "Preservation specification" on page 41
For Geared variable speed couplings that are to be stored for longer than 12 months, Preservation/corrosion
Voith Turbo GmbH & Co. KG Crailsheim offers special long-term corrosion prevention prevention after
with instructions for storage after delivery. delivery
-+ Appendix_A_ "Preservation method and instructions for storage after delivery

3625-006714;;
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4.4 Unpacking, transportation
The Geared variable speed coupling is delivered with transport rails in place. If neces
sary, it is also protected by a crate. Both the coupling and the crate have specified lif
ting points.
1. If necessary, remove the crate.
Risk of Injury
Improper lifting of the Geared variable speed coupling

can result in equipment damage and personal injury.
The Geared variable speed coupling is to be

suspended only from the specified lifting points and in
compliance with the ~ 150 angle of inclination as well
as the minimum crane hook height H.
Use only appropriate lifting appliances that conform to

safety requirements!
Equipment damage
Transporting and setting the Geared variable speed
coupling down improperly can results in damage to
the coupling.
The Geared variable speed coupling is to be
transported only when it is properly secured and with
the transport rails attached!
Set it down only on a firm and appropriate surface!
Rest it only on the feet attached to the housing or the
feet attached to the oil reservoir!
NOTE
The lifting points provided on the Geared variable speed coupling are intended
only for the weight of the coupling itself.
Do not lift any other equipment at the same time! The Geared variable speed
coupling is to be lifted only without oil in it!
35
VOITM
2. Before using, inspect swivels (1) and lifting points for proper assembly and instal
lation, cracks, deformation and corrosion (see "Inspecting and servicing prior to
use" on page 39). Place chain links in the correct position (see Illustration 4-5 • ,Po
sition of chain links").
3. The Geared variable speed coupling is to be suspended only from the specified lift
ing points (2) and in compliance wit the:$; 15 0 angle of inclination as well as the
minimum crane hook height H (see "Instructions for lifting" on page 39).
Illustration 4-4:
Swivels/lifting points
Lifting points
2 Sticker
Illustration 4-5:
Position of chain links
Proper use Improper use
Illustration 4-6:
Suspension sketch
Angle of inclination
Crane hook height H
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If the minimum crane hook height is not available H, the coupling can be lifted
with a crossbar as an alternative (see Illustration 4-7 "Example of a crossbar'').
4. Unscrew the transport rails from the coupling.
5. Set the Geared variable speed coupling down on the feet attached to the oil reser
voir.
37
VOITM
4.4.1 Lifting with swivels
Failure of lifting points and swivels poses an immediate risk to the safety and health Use and attachment
of individuals in the danger zone during a lifting operation.
Only trained and regularly instructed personnel must be permitted to use lifting gear General prinCiples
for assembly transport and maintenance.
Prior to using such gear, the designated personnel must receive instruction from
knowledgeable individuals.
Swivels may be used only for items supplied by Voith for use with the Geared variable
speed coupling. Additional weights (other attaching parts) must not be lifted at the
same time.
Swivels and lifting points must not be exposed to acid vapors. The effects on functio
nal integrity must also be checked in other corrosive environments.
Swivels and lifting points must be protected against physical damage.
Service temperature range "t" for swivels

-40°C < t ~ +200 °C
The following applies to TAWGK swivels: Assembly
• Lifting points (contact surface and coupling housing) and swivels must not have
been damaged by sharp-edged loads.
• Swivels must be tightened with a torque wrench.
• Apply Loctite ™272 to swivel threads.
• If used in a corrosive environment, protect the lifting point and swivel.
Tightening torque for swivels

Dimensions Designation Tightening torque Wrench size
M 30 x45 TAWGK8 270 Nm 65mm
M 36 x 54 TAWGK8 270 Nm 65mm
M64x110 TAWGK20 500 Nm 105 mm
38
VOITM
• Before lifting the load, check the inclination angle. Instructions for
• The inclination angle must be ::; 15 o. lifting
• Observe the minimum crane hook height H.
• The coupling may be transported only as depicted; twisting and turning the load as
well as pulling the load from one side by means of the lifting points is prohibited
(see Illustration 4-6 "Suspension sketch;,).
• As an alternative, the coupling can be suspended from a crossbar if the minimum
crane hook height is not available (see llIustration 4-7 "Example of a crossbar").
• Before attaching, properly orient the chain links (see Illustration 4-5 "Position of
chain links").
• Swivels may be used only for items supplied by Voith for use with the Geared vari
able speed coupling, see assembly plan. Additional weights (other attachments)
must not be lifted at the same time.
• The following cranes may be used (hoisting class to DIN 15018): hoisting class
H1, H2, H3, H4 with a max. lifting speed of 10 m/min.
Illustration 4-7:
Example of a crossbar
Lifting points are to be inspected by a qualified individual after installation of the cou- Inspecting and
piing at the intended site and at least once yearly thereafter. serVicing prior to
use
Before using, inspect swivels and lifting points for proper assembly and installation,
cracks, deformation and corrosion. Surfaces must undergo a crack test every 3 years.
• Integrity of the lifting poinVsling swivel Points to be

• Ensure that they are screwed in tightly, check the tightening torque. inspected and
• Do not exceed the load-carrying capacity. criteria for use
• Use the correct bolts and bolt lengths.
• Swivels and lifting points must not be used outside the specified service tempera
ture range.
• Use is prohibited immediately upon detection of cracks.
• Use is prohibited immediately upon detection of damage to threads, chain links or
lifting points. The current inspection criteria apply.
39
VOITM
• Use is prohibited immediately upon detection of severe corrosion.

• Use is prohibited immediately as soon as the maximum clearance >s< is exceeded
(see Illustration 4-8 "Max. dearance >s<')
The following applies to all swivels: If the maximum clearance >s< is exceeded, the Clearance >s<
swivels may no longer be used.
Illustration 4-8:
Max. clearance >s<
);:9~~....... -J ..- Max. clearance between

upper and lower parts >s<
Sling swivel designation Max. clearance >s<
TAWGK8 3.2mm
TAWGK20 4.5 mm
40
VOITM
4.5 Preservation specification
Source: Sheet 3625-006212 de, date of issue: November 2002
These specifications apply to protection of internal and external surfaces (insofar as

the surfaces are not treated and/or corrosion-resistant or made of cast aluminum), as
well as the packing of shipments.
Overview
Preservation
Transport, storage and dura- Internal with Internal without

Packaging No. External
tlon of storage test run test run
• Overland/air transport for imme- Packaging External preserva- Internal preserva- Internal preserva
diate installation at the destina- No.1 tion no. 1 tion no. 1 tion no. 2
tion (or storage in a closed build

ing for up to 6 months)
• Sea transport and / or storage for Packaging
up to 12 months after the date of No.2
packaging
• Sea transport and / or storage for Packaging
up to 24 months after the date of No.3
packaging
• Extended protection (after expira- Replace plastic film External preserva- Internal preservation no. 3
tion of the initial protection) and reseal tion no. 2
• Paint finish as specified in order documents. External preser

• Bare iron parts sprayed with "Shell Ensis Fluid S,,1). vation no. 1
• See note.
• Paint finish as specified in order documents. External preser

• If necessary, reapply depending on the condition of preservation no. 1. vation no. 2
• Exchange desiccant.
NOTE
If use of vel preservation products for an order if ensured throughout the entire
packaging chain, corrosion protection based on this preservation method is
permissible if agreed upon.
1. Before installing the coupling or parts, clean sprayed surfaces with solvent (white spirits or petro
leum).
41
VOITM
• Internal preservation from oil used during test run. Internal preser
• If the order documents call for "Inspection" after the test run, spray with solvent vation
free corrosion-inhibiting oil ("Shell Ensis Engine Oil 20" used at the factory) to the no. 1
extent possible. For alternatives to "Shell Ensis Engine Oil 20" see 3625-006237).
• Fill the interior of the coupling with dry air, relative humidity max. 10%.
• All surfaces of iron parts (including holes, cavities and internal surfaces of pipes) Internal preser
sprayed, immersed or flushed with solvent-free corrosion-inhibiting oil during as vation
sembly (with Shell Ensis Engine Oil 20 at the factory) based on installation no.2
progress. All assemblies sprayed during assembly to the extent possible. For alter
natives to "Shell Ensis Engine Oil 20" see 3625-006237).
• Fill the interior of the coupling with dry air, relative humidity max. 10%.
• Inspect the preservation. Internal preser

• Spray all rotating parts and wall surfaces with solvent-free corrosion-inhibiting oil vation
(e.g. "Shell Ensis Engine Oil 20"), turn rotating parts while spraying. For alterna no.3
tives to "Shell Ensis Engine Oil 20" see 3625-006237).
• Spray the inside of piping with solvent-free corrosion-iinhibiting oil (see above).
As an alternative, fill the interior of the coupling with dry air, relative humidity
max. 10%.
• To the extent possible, fill the interior of the coupling with dry air, relative humidity
max. 10%.
• Means suitable for transport (e. g. transport frame, holder, support) Packaging no. 11
• Transport means provides protection from the weather.
• Means suitable for transport (e. g. transport frame, holder, support) Packaging no. 21
• Sharp edges and supporting surfaces covered with elastic materials.
• Sealed in PE film.
• Desiccant in acc. with DIN 55 473/55 474.
• Water-resistant carton or wooden crate.
• Inside of crate lid covered with closed ribbed PE sheets (Akylux). With PVC film
underneath at butt joints.
Identical to packaging no.2. Difference: sealed in aluminized plastic film instead of PE Packaging no. 3
film.
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VOITN
4.5.1 Internal corrosion-inhibiting oils
NOTE
The Geared variable speed coupling is not filled with working oill
Source: Sheet 3625-006237 de, date of issue: June 1996
HD engine oils with especially pronounced anti-corrosion properties are recommen

ded as alternative corrosion-inhibiting oils. Special ingredients in these solvent-free
corrosion-inhibiting oils promote the formation of strongly adhering protective films
that protect vertical surfaces effectively.
(Shell Ensis Engine Oil 20 used at the factory)
Recommended
Supplier Designation grades:
AGIP AGIP RUSTICA 10W-20
ARAL ARAL Oel KONIT SAE 20 W 20
DEA DEA DEAMOT EKM 162 N (SAE 20 W-20)
ESSO ESSO MKZ Engine Oil HD 20W-20
FINA FINA RUSAN MOTOR OIL SAE 20 W-20
MOBIL MOBILARMA 524 (SAE 30)
SHELL SHELL Ensis Engine Oil 20
WINTERSHALL WINTERSHALL Antikorrol 20 W-20
(This list makes no claim regarding completeness.)
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4.5.2 To be ensured at the installation site:
Special attention should be paid to the effectiveness of the preservation applied to Installed units or
these units, since it often subjected to additional hazards such as water, accumulation units ready for
of large amounts of dirt and physical damage. Installation
This includes measures that provide supplemental internal protection when idle times Complete systems
of up to about 12 months are to be expected and when the original corrosion preven Installed on a
tion coating has been disturbed. foundation
Fill units with water-free working oil. The following can be performed at intervals of 1
2 months, depending on the state of installation:
• System that is ready to operate:

- Start and operate only briefly (approx. 5 minutes) to coat the surface of internal
parts with oil; do not run until warm.
• System that is not ready to operate:

- Units with a ready-to-operate electric auxiliary lube oil pump or oil pump and oil
reservoir:
- Switch on pump; allow system to operate, if possible. Move operating compo
nents (e. g. joints).
- Units without a ready-to-operate electric auxiliary lube oil pump or oil pump:
- Remove oil from the sump, spray inside through openings in the housing and
circulate oil through the piping with the aid of a separate oil pump, run for ap
prox 5 minutes: allow system to operate, if possible. Move operating compo
nents (e. g. jOints).
NOTE
Before filling with the working fluids, contact the suppliers to confirm
compatibility with the internal corrosion preventative.
44
VOITH
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M 5 Configuration
5 Configuration
Hazard from Improper Installation
Improperly installed or assembled components could loosen, electrical lines could be
incorrectly connected or routed, the insulation on poorly routed cables could be abra
ded and, as a result, cause serious personal injury or equipment damage.
Only a qualified electrician who is knowledgeable about rules that apply to electronic
equipment in the country of installation is allowed to perform work involving the elec
trical equipment on the Geared variable speed coupling.
Use only cables with insulation that can withstand the ambient operating conditions!
Hazard from unseen areas
An individual could be seriously injured while handling the equipment if it starts up un
expectedly.
Attach suitable guarding between the coupling and shaft that can only be removed by
using tools!
Work on the equipment only after the power has been disconnected (no voltage pre
sent)!
Operate the equipment only after visually confirming that no one is in a danger zone!
Hazard from maximum pressures, pressure shocks, pressure rise or pressure

loss
An unsuitable or poorly maintained heat exchanger, improperly sized oil lines, the ab
sence of shutoff valves, incorrectly set pressure relief valves or an improperly installed
check valve could result in high pressures that could destroy the equipment, causing
serious personal injury due to flying objects as well as damage to the environment. A
severe pressure drop could damage bearings.
- Allow only trained personnel to perform installation, maintenance and service

work on the equipment and to operate it!
- Confirm that check valves are installed correctly!
- Observe maintenance intervals!
- Comply with limits!
- Do not install shutoff valves in the oil circuit, make sure that the oil circuit con
forms to the schematic provided!
45
VOITN
Equipment damage
Creepage or stray electric currents can reach the Geared variable speed coupling via
the drive shaft, leading to spark erosion damage on bearing surfaces and the surfaces
of teeth on the drive gears in the pump insert.
Provide appropriate grounding / insulation between the driving machine (e.g. between
the connecting coupling) and take the necessary measures to interrupt the flow of
electric current!
Equipment damage
Dirt caused by construction, flying sparks, grinding dust and water can get into the
Geared variable speed coupling and cause the equipment to malfunction.
Cover the Geared variable speed coupling with a tarpaulin completely during
I
construction work at the installation site!
Protect instruments, electrical cables and cable trays particularly well!
Use only appropriate sealants that are oil resistant up to 130°C and do not contain si
licone. Failure to comply with the above will have an adverse effect on oil quality and
can cause damage to the Geared variable speed coupling.
Equipment damage
Improper installation can result in malfunctions and premature wear in the equipment.
Setup and initial commissioning should be performed by a Voith technician!
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5.2 Tools and other aids
• Metric tools
• Torque wrench
• Sealing compound (must not contain silicone) "Sealant" on page 120
• Lifting appliances
• Device for mounting the coupling hubs
• Shims
• Adjusting screws on the foundation rails for horizontal alignment
• Adjusting screws for vertical alignment
• Alignment device
5.2.1 How to seal the keyway
How to seal the keyway in the case of an oil-filled or grease-filled connecting coupling.
• Connecting coupling hub provided or still to be provided with a tapped hole above
the keyway.
• Mount the hub on the shaft.
• Fill the tapped hole 2/3 with the sealing compound 1•
• Insert and tighten set screw. Remove any sealing compound squeezed out of the
face side.
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VOITN
5.3 Checking the concrete foundation
• Are the foundations for all machines in the system properly sized? (height, center
position, flatness)
• Is the height of the concrete foundation such that there is a clearance of 100 mm
between the geared variable speed coupling and the foundation?
• It is recommended that the foundation be painted with oil-resistant paint so that oil
cannot seep into the foundation and damage the concrete.
5.4 How to set the steel plates around the anchor holes
1. Set the steel plates around the 6 anchor holes in the concrete foundation using an
epoxy compound (e.g. EPOCAST 36).
Align the plates with a level (maintain specified distance to reference point, e.g. shaft
centerline or a-line).
When positioning these plates, ensure that subsequent insertion of the anchor bolts
and grouting of the anchor holes remain possible.
Illustration 5-9:
Placement of the anchor
bolts, adjusting bolts
and steel plate
1) Anchor bolt
2) Adjusting bolt
3) Steel plate
4) Epoxy compound
48
VOITH
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 M 5 Configuration
5.5 Mounting the connecting couplings
NOTE
Gear couplings or all-metal couplings with low radial restoring forces are
suitable. Connecting couplings with a flexible compensating element (flexible
element) are to be agreed upon only in individual cases.
If the connecting couplings are being supplied by Voith or have been provided by the Factory mounting
customer, the input- and output-side connecting coupling halves will have been moun
ted at the factory:
• The end cover (2) and coupling hub (3) have been mounted on the shaft ends (1)
• The coupling sleeves are packaged separately.
Illustration 5-10:
Coupling hub on shaft
Shaft end
! 2 End cover
3 Coupling hub
4
5
mounting device
Plate
Bolt
6 Threaded spindle
If the connecting couplings are not yet mounted: On-site mounting
-+ (manufacturer's specification for connecting coupling)
NOTE
Check the connecting coupling for existence of the puller thread at the face end
and tapped hole above the keyway.
49
VOITH
1. Clean the shaft (1) and hub (3) from preservation agents using gasoline or cellu Gear couplings with
lose thinner (not petroleum) and degrease. key
2. Check the bore, shaft, key and keyway for dimensional accuracy.
3. Remove the key from the shaft keyway and fit it into the hub keyway. Then fit the
key into the shaft keyway again. Check the height of the key: the back clearance
between the keyway and key must be 0.2-0.3 mm.
4. Apply a thin coat of Molykote D Paste 1 or an equivalent lubricant to the shaft.
5. Slide the end cover (2) and D-rings over the shaft end.
6. Mount the coupling hub using a hub puller (4, 5, 6).
7. Seal the keyway of the connecting coupling hub (Section 5.2.1 ,.How to sea! the
8. Connecting couplings without an intermediate piece: slide the sleeve over the hub.
9. Connecting couplings with an intermediate piece: mount the sleeve only after
alignment.
1a.Protect the connecting couplings against corrosion and cover them.
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5.6 How to install the oil drain line with valve or pump
After the Geared variable speed coupling has been installed, the bottom of the oil re
servoir with the connection for the oil drain line is, in most cases, not accessible.
Therefore, perform the following actions prior to positioning the Geared variable
speed coupling:
When removing the screw plug or blind flange, a small

amount of residual corrosion-preventing oil may drain
out; this oil could seep into the ground.
Collect the oil in a flat container and dispose of it in a

professional manner!
1. Remove the screw plug or blind flange from the connection for the oil drain line and Installing the oil
collect any oil that drains out. drain line with valve
2. Attach the valve to the oil drain line and install the complete linelvalve assembly.
Close the valve.
3. Apply a corrosion inhibitor to the line (corrosion protection).
Another possibility for removing the oil from the reservoir. Installing the pump
NOTE
To empty the oil reservoir by means of a pump, the pump must be a self-priming
type.
1. Remove the blind flange from the oil suction connection (see location of item L\ in
the "Assembly Plan").
2. Connect the self-priming pump.
3. Install a flange, screw plug or valve in the attached oil line and close off the line.
51
VOITN
5.7 Setting the geared variable speed coupling down on a

concrete foundation
Illustration 5-11:
Anchoring the geared
variable speed coupling
1) Anchor bolt
2) Adjusting bolt
3) Steel plate
4) Base plate
Checks: Prior to setting

down
• Are the connecting coupling sleeves mounted or has a sufficient distance been
provided between the shafts for connecting couplings with an intermediate piece,
in order to mount the sleeve later?
• If the driven machine has been installed, check the axial clearance and, if neces
sary, move the rotor into the operating position (magnetic means). The driven ma
chine is normally fixed axially, but this should be checked.
• When setting the equipment down on the foundation, ensure the correct axial
spacing between the connecting couplings.
1. Place the anchor bolts in the base plate such that two threads protrude past the
nut. Wind the anchor bolts with insulating tape, see Assembly diagram.
2. Thread the adjusting bolts into the base plate.

The distance between the head of the bolt and base plate must be determined, see
eli
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r:
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same for all adjusting bolts.
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", so that both parts slide on one another easily when aligning the equipment.
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5.8 Preliminary alignment and grouting of the anchor bolts
Illustration 5-12:
Preliminary alignment
1) Base plate
2) Adjusting bolt
3) Steel plate
4) Adjusting bolts
5) Alignment bracket
1. Set the geared variable speed coupling down on the concrete foundation with the Setting down
aid of suitable lifting appliances. Maintain the specified axial clearance between
the connecting couplings.
2. Place the alignment bracket on the foundation.
3. Adjust the height of the geared variable speed coupling using the adjusting bolts.
4. Align laterally by moving the geared variable speed coupling on the steel plates,
the surfaces of which have been greased.
The system components must be aligned with one another. Preliminary

alignment
Normal alignment sequence:
1. Align the geared variable speed coupling with the driven machine.
2. Align the driving machine with respect to the geared variable speed coupling
-+ For measurements, see Section 5,9 "Machine alignment".
NOTE
All machines involved (driving machine, geared variable speed coupling, driven
machine) should be set in position prior to performing the alignment.
iii
J:
t 1. Place the anchor bolts in the center of the holes in the base plate. Grouting of anchor
bolts
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2. Grout the holes in the concrete foundation completely using wet concrete mixture ..
Concrete grout - mixing proportion:

1 part cement and 2 parts sand
3. The setting time of the concrete grout is about three days.
Any lateral deviations are corrected during final alignment using the adjusting bolts in Final alignment
the horizontal position.
Deviations in the height are corrected using the adjusting bolts in the base plate of the
geared variable speed coupling.
-+ For measurements, see Section 5.9 ,.Machine alignment".
Secure the geared variable speed coupling in accordance with Section 5.10
the machine to the foundation".
54
VOITM
Voith Turbo I Geared variable speed coupling I SEC S61ndonesia Pelabuhan I R 15 K 400 M 5 Configuration
5.9 Machine alignment
The system components must be aligned with one another. All machines must be at
the standstill temperature. At operating temperature, the shafts must be optimally ali
gned.
Normal alignment sequence:
1. Align the Geared variable speed coupling with the driven machine
2. Align the driving machine with the Geared variable speed coupling
NOTE
The machine alignment procedure described here is based on a measuring
method using dial indicators. It is also possible to use equivalent systems such
as "electronic / optical measuring methods", for example, the electronic CTC
measuring method, Optalin measuring system or Indikon measuring system as
well as others.
Additional information regarding alignment can be found in VDI Directive VDI
2726 "Alignment of Gearboxes", manual for practical use "Alignment of Shafts
in Machine Sets", VDI Publishers.
5.9.1 Shaft misalignment and alignment tolerance
When aligning the Geared variable speed coupling, dimensional Changes arising from Shaft misalignment
the following must be taken into account:
• Warming and expansion of the housing during operation and

• Rotation-dependent shaft misalignment due to tooth forces, bearing clearances
and hydrodynamic lubrication.
55
VOITN
Illustration 5-13:
Radial and
axial displacement
I Input end
II Output end
Radial displacement
0 0 0 0 0 0 0 0 horizontally ah and
0 0 0
0 0 0 0
vertically a v
Axial displacement
dL dL
dL2
ah1
t1)-' ah2
Radial displacement, horizontal 1
input side (drive side) ah1 0.07 mm
• output side (driven side) ah2 0.10 mm
Radial displacement, vertical 1
• input side (drive side) av1 0.24 mm
• output side (driven side) av2 0.24 mm
Axial displacement 1
input side (drive side) dL 1 0.40 mm
• output side (driven side) dL2 0.40 mm
1. assumed housing temperature: 20°C at installation, 60°C during operation
This means that the shafts connected by means of connecting couplings should not
be aligned at standstill, but rather must have a radial/angular/axial offset. This offset
t
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compensates for the displacement arising at startup and during operation.
56
VOITM
Voith Turbo I Geared variable speed coupling I SEC 56 Indonesia Pelabuhan I R 15 K 400 M 5 Configuration
When rotating both shafts by 360 0 : Alignment tolerance

at operating temper
• Radial measurement A: radial misalignment ± 0.03 mm
ature
• Angular measurements Band C: Angular misalignment ± 0.03 mm/1 00 mm
Radius Rm
Illustration 5-14:
Angular displacement
and radial offset
1 Machine aligned
2 Machine still to be
aligned
Radial offset
horizontally ah and
vertically av
Angular misalign
ment
horizontally b h and
vertically bv
Radius Rm
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5.9.2 Connecting couplings with an intermediate piece
In most cases, a connecting coupling with an intermediate piece is placed between

the driven machine and the Geared variable speed coupling, i.e. there is a space bet
ween the shaft ends.
Illustration 5-15:
Alignment using the
alignment device for
connecting couplings
with an intermediate
piece
Machine aligned
2 Machine still to be
aligned
3 Alignment device
with dial indicators
1. Fabricate a solid alignment device out of flat stock, round bar stock and steel pro
files (3) and bolt to the shaft end of the machine to be aligned (2).
NOTE
The initial value or reading on the dial indicator can be 5.00 as assumed in the
following examples.
2. Insert the dial indicators so that they are free from play and secure them.
3. Check the radial runout of the already aligned machine (1): rotate the shaft (1) by Radial runout check
360°.
Value to be aimed at: dial indicator deflection::; 0.02 mm;
~ permissible value: see instruction manual of driven machine.

!"iii
58
VOITH
4. Reset the dial indicators to the initial value. Precision alignment

in the vertical plane
5. Rotate shaft (2) by 180°.
6. Enter the dial indicator deflection in the coordinate system of the installation check
form.
Illustration 5-16:
18=5.001 Example of radial
measurement A and
IA=5.001 C=6.55 18=5.001 C=6.55
angular measurements
-¢- -¢- --1-~-1-~--

Band C in the vertical
plane
A =4.66 8=5.45 I c=5.001 8=5.45

I c=5.001
Evaluation:
Radial measurement A:
Radial misalignment , vertical = 5,00 - 4,66 = 0 17

2'
mm
Angle measurement 8+C:
Angular misalignment , vertical = 6,55 2

- 5, 45 = 0 55 mm
'
For the angular measurements: half of the difference between two angular meas
urements is the amount of the angular misalignment.
7. Correct the vertical radial offset and the vertical angular misalignment by means of
the adjusting bolts.
8. Place the alignment device (3) in the horizontal position (rotate 90° with respect to Precision alignment
the original position). in the horizontal
plane
9. Repeat the measurement.
Illustration 5-17:
Example of radial
A=528 AIA=5001 18=5,001
Ic =5,00 I measurement and
, ~ , C=~~
8 =4,65 angular measurement in
the horizontal plane
Evaluation:
Radial measurement A:
Radial misalignment , horizontal = 5,28 - 5,00 = 0 14

2'
mm
Angle measurement 8+C:
Angular misalignment, horizontal = 4, 65 ; 4, 55 = 0, 05 mm
59
VOITM
1O.Move the Geared variable speed coupling horizontally using the adjusting bolts
and in this way correct the horizontal radial offset and the horizontal angular mis
alignment.
5.9.3 Connecting couplings without an intermediate piece
In most cases, a connecting coupling without an intermediate piece is placed between

the driving machine and the Geared variable speed coupling, i.e. there is no space
between the shaft ends.
Prior to performing the precision alignment, it is advisable to first align the machines Rough alignment
roughly use a feeler gauge and straightedge.
Illustration 5-18:
Rough alignment of
without an intermediate
piece
Straightedge
2 Feeler gauge
3 Coupling sleeve
4 Coupling hub
5 End cover
1. Check the shaft spacing using the thickness gauge (2).
2. Check the radial and axial misalignment with a short straightedge (1).
Following this, align the machine precisely using an alignment device with dial indica Precision alignment
tors. in the vertical plane
60
VOITM
I/Iustration 5-19:
Rough alignment of
without an intermediate
piece
Alignment device
with dial indicators
2 Coupling hub
3 End cover
4 Coupling sleeve
5 Bolt
6 Spacer
3. Fabricate an alignment device out of flat bar stock (1) and attach it to the shafts.
NOTE
The initial value or reading on the dial indicator can be 5.00 as assumed in the
following examples!
4. Insert the dial indicators so that they are free from play and secure them.
5. Connect the sleeves of the connecting couplings (4) with each other using 2 bolts
(5) and 2 spacers (6) of about 20 mm.
6. Slide the flat steel between the two sleeves and rotate the two shafts by 1800 •
7. Continue measuring in the vertical and horizontal planes as outlined in

Section 5.9.2 "Connecting couplings with an intermediate piece".
61
VOITM
5.10 Securing the machine to the foundation
Illustration 5-20:
Securing to the
foundation
1) Flat bar stock

2) Steel plate
3) Adjusting bolt
4) Anchor bolt
1. Check that all adjusting bolts are supporting the load evenly.
2. Tighten the anchor bolts.
3. Check the alignment.
4. Record the final measurements in the coordinate system of the installation check
form.
5. Secure the adjusting bolts to the steel plates to prevent them from turning.
This can be accomplished by welding flat bar stock to the steel plates (see
lI!ustration 5-20 "Securing to the foundation").
6. Spray the anchor bolts, adjusting bolts and steel plates with corrosion inhibitor.
5.10.1 Realigning the entire system at a future date
If the entire system is to be realigned after a long period of operation, the geared var
iable speed coupling will have to be shifted on the steel plates. With the anchor bolts
centered in the base plate, they will have enough clearance for movement in the
holes.
After grinding off the welded-on flat bar stock, the shaft height is set by turning the ad
justing bolts.
After the realignment, secure the adjusting bolts to the steel plates to prevent them
from turning. This can be accomplished by welding flat bar stock to the steel plates
(see Illustration 5-20 "Securing to the foundation").
62
VOITH
5.11 Plumbing the machine to the heat exchanger
For installation dimensions for the heat exchanger:
-+ see the heat exchanger installation diagram in Chapter 14 "Attaching parts" of the
documentation.
5.11.1 Installing the heat exchanger
If the heat exchanger is installed such that the pipes rise when viewed from the
Geared variable speed coupling, the oil cooler and piping will empty into the
Geared variable speed coupling when the system is shut down, causing the
Geared variable speed coupling to overfill and leak on startup. The temperature
will exceed the permissible value and the fusible plugs will melt.
If possible, install the heat exchanger below the level of the oil in the Geared
variable speed coupling! Take the necessary measures when installing it above
the oil level!
63
VOITN
5.11.2 Horizontal heat exchangers
Illustration 5-21:
H1 H2 Horizontal heat
exchangers
Lube oil heat ex

changer
2 Working oil
heat exchanger
3 Vent line
4 Oil compensating
line
H1 H2 H3
Both heat exchangers below the Both heat exchangers at the same height Both heat exchangers at the same
Geared variable speed coupling and as the Geared variable speed coupling height as the Geared variable speed
positioned horizontally next to one and positioned horizontally next to one coupling and positioned above one an
another 1 another1 other 1
Piping and heat exchanger cannot Pipes and heat exchanger can drain.
drain.
Measures: run the oil supply and return lines to the heat exchanger siphon-like in an
Run the pipes to the heat exchanger upward direction and, at the highest point, connect an oil compensating line 2 DN 8
horizontally or descending, if possi- (4). Run the lines below the oil level of the Geared variable speed coupling.
ble. Favorable.
1. Working oil cooler shell vented three times, with collection line and return line to the Geared variable speed coupling housing.
(Section 5.11.5 "Installing the vent lines"')
2. Install an orifice plug with a 3 mm orifice opening in the oil compensating line.
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5.11.3 Vertical heat exchangers
Illustration 5-22:
V3 Vertical heat
exchangers
V2
Lube oil heat ex
changer
2 Working oil
heat exchanger
3 Vent line combined
with oil compensat
ing line
V1
4 Vent (bleeder) valve
5 Check valve
V1 V2 V3N4
Both heat exchangers below the Both heat exchangers below the Both heat exchangers at the same height as
Geared variable speed coupling Geared variable s~eed coupling and in the Geared variable speed coupling and in a
and in a vertical position against a vertical position vertical position
the wall 1
Piping and heat exchanger cannot drain. Run the pipes to the heat ex Pipes and heat exchanger can drain. Meas
changer horizontally or descending, if possible. ures:
Favorable. Run the lines below the oil level of the

• V3: Install the check valve (5) in the sup

ply line to the cooler and the vent valve
(4) in the return line from the cooler with
discharge into the coupling housing.
• V4 (not shown): similar to V3, but without

the check valve. Run the oil supply and
return lines to the heat exchanger si
phon-like in an upward direction and, at
the highest point, connect an oil compen
sating line DN 8 (4).
1. similar to H1, but without heat exchanger venting
65
VOITM
5.11.4 Installing the oil lines
It is preferable to run the oil lines below the oil level in the Geared variable
speed coupling.
The oil lines should be as short as possible « 8 m). In the case of longer lines that
run above the oil level in the Geared variable speed coupling, install a check valve in
the oil line from the Geared variable speed coupling to the heat exchanger and follow
the installation instructions for heat exchangers (Illustration 5-21 "Horizontal heat ex
on page 64 and Illustration 5-22 "Vertical heat exchangers" on page 65).
Size the oil lines upstream and downstream of the heat exchanger to allow the lube oil
and working oil to flow at a velocity between 1.0 mls and 4.0 m/s.
Maintain a constant oil line diameter over the entire length. In the case of larger con
nections on the cooler, increase the line size directly at the cooler.
~ (Heat
exchanger installation diagram in Chapter 14 "Attaching parts" of this Instruc
tion Manual)
The machine is aligned exactly. Prerequisite
1. Remove the weld-neck flanges from the machine. Installing the oil
lines
2. Connect the Geared variable speed coupling to the heat exchanger as shown in
Illustration 5-21 "Horizontal heat exchangers" and Illustration 5-22 "Vertical heat ex
. Ensure that the installed piping is free from stress.
3. Support the lines.
4. Horizontal heat exchangers H1-H3:

- Attach a collection line (Illustration 5-23 "Vent line for working oil heat ex
changer", item 1) to the vent connection (Illustration 5-23 ,,Vent line for working
oil heat exchanger", item 3) of the heat exchanger to vent the shell.
- Attach a drain line with shutoff valve to the drain connection (illustration 5-23
"Vent line for working oil heat exchanger", item 4) of the working oil heat ex
changer.
5. Install the external lube oil lines (e.g. for the driving machine, driven machine and
lor the connecting couplings.
6. Switch on the auxiliary lube oil pump. Pilot drill orifices at the lube oil outlets from Drilling of orifices
the Geared variable speed coupling to the driving machine and driven machine or for lube oil supplied
install already pilot drilled orifices. to external units
66
VOITM
Voith Turbo I Geared variable speed coupling I SEC S61ndonesia Pelabuhan I R 15 K 400 M 5 Configuration
The lube oil flow rate and lube oil pressure for external units depend on the dia
meter of these orifices and possibly on additional orifices upstream of bearing lo
cations on the driving and driven machines.
-+ For diameters of orifice holes, please refer to Section 5.14 "Orifice holes for lube
oil supply to external units" in the appendix to this chapter.

-+ For required lube oil flow rates, please refer to Section 1.2 "Operating data".
5.11.5 Installing the vent lines
It is necessary to vent the working 011 heat exchanger continuously. Working oil heat
exchanger vent line
(H1, H2, H3, V3)
Tube bundle - heat exchanger
Illustration 5-23:
Vent line for working oil
1 heat exchanger
1 Collection line
2 Screw-in orifice
3 Vent connection
4 Drain connection
~
5 Coupling housing
---i,·-d-tH
u~
Install the vent line as shown in Illustration 5-23 ,Yent line for working oil heat ex
changer" :
1. Insert three screw-in orifices (2) at the three vent connections (3) in the oil cooler
shell.
Orifice size for normal cooler oil pressure 4 mm.
2. Connect the orifices to a collection line DN 20 (1).
@ 3. Run the collection line to the Geared variable speed coupling (5) (see installation
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diagram for tie-in point).
When installing the heat exchanger above the oil level in the Geared variable speed Oil compensating
coupling, the oil compensating line (H2, H3, V4) or the vent line (V3) between the two line ON 8 (H2, H3,
siphon-like line segments prevents the heat exchangers from draining when the V4), vent line (V3)
equipment is at a standstill.
Attach oil compensating line and vent line as shown in Illustration 5-21 "Horizontal heat
exchangers" and Illustration 5-22 heat exchangers".
67
VOITM
Voith Turbo I Geared variable speed coupling I SEC 56 Indonesia Pelabuhan I R 15 K 400 M 5 Configuration
5.11.6 Pickling of oil lines
NOTE
Before preparing this or another pickle, be sure to read and understand the
specifications, safety information (data sheets) and application information.
Hazard from dangerous substances
Hazardous substances (pickling solutions) can cause

injuries or burns.
Wear personal protective equipment, especially

safety goggles, when cleaning and pickling oil lines!
011 lines assembled and welded on site must be disassembled and pickled in an im- Pickling oil lines
mersion bath to ensure that they are free from scale and rust. Only then can they be made of steel
reassembled and flushed. (neither rust-proof
nor acid-proof)
1. Unscrew the oil lines.
2. Degrease heavily oiled or greased workpieces prior to pickling, e.g. by means of
steam cleaning or immersion in a degreasing bath.
3. Mix the pickle 1 with water.
4. To remove dirt, light oil films, graphite or carbon deposits: add pickling degreaser2
to the pickle.
5. Heat the solution to 40 cc.

6. Place parts into the pickle.
7. Remove the parts from the pickle. After pickling, they should be bright and free
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Recommendation: product 813, manufacturer Karowa Co., Memmingerstr. 39A, Neu-Ulm, Ger
many, or equivalent pickle. Mixture: 1-31 to 100 I of pickling solution.
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VOITN
Pickling period
Rust film approx. 5-10 min.
Rust approx. 15-30 min.
Rolling skin approx. 50 min.
Descaling of annealed steel parts approx. 120 min.
8. Allow the parts to dry protected from dripping water (24-48 hours at 20°C). Do not
wash off! If the drying time cannot be observed, rinse again with clean water.
9. Spray parts internally with the working oil and externally with paint.
Oil lines assembled and welded on site must be disassembled and pickled in an im Pickling of oil lines
mersion bath to ensure that they are free from scale, temper colors and rust. Only made of rust-proof
then can they be reassembled and flushed. and acid-proof steel
(stainless steel)
NOTE
Before preparing this or another pickle, be sure to read and understand the
specifications, safety information (data sheets) and application information.
1. Unscrew the 011 lines.
2. Degrease heavily oiled or greased workpieces prior to pickling, e.g. by means of
steam cleaning or immersion in a degreasing bath 1.
3. Prepare the pickle 2 .
4. Place parts into the pickle.
5. Remove the parts from the pickle. After pickling, they should be bright and free
from scale and rust.
The pickling period depends on the

- Temperature and
ci5 - Life (age of the pickle)
I
Om Pickling procedure for materials with the materials nos.1.4541, 1.4550, 1.4571.
1. Recommendation: product DERUSTIT 1622, manufacturer Deutsche Derustit GmbH' Emil von Be
hringstrasse 4 • Dietzenbach/Germany • or equivalent degreaser.
2. Recommendation: product DERUSTIT pickle 1234, manufacturer Deutsche Derustit GmbH' Emil 69
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VOITN
Age of pickle Pickling period
New pickle up to 1 week old 20 to 30 min.
1 to 4 weeks 40 to 60 min.
4 weeks and older up to 120 min.
Pickling procedure for materials with the

material nos. 1.4301, 1.4306, 1.4401
Age of pickle Pickling period
New pickle up to 1 week old 10to15min.
1 to 4 weeks 20 to 30 min.
4 weeks and older 60 to 120 min.
Pickle that escapes into the sewers or ground can

cause damage to the environment.
Dispose of used pickle in a proper manner that

complies with national statutory regulations.
6. Flush the part with water 1 , making sure to comply with protection regulations.
7. Spray the wet parts with a passivation solution 2 .
8. For final cleaning of the parts, flush them with water2.
9. Let the parts dry in clean rooms. Allow parts with cavities to dry in pure nitrogen.
10.Spray parts internally with the working oil and externally with paint.
1. High pressure 160 bar

2. DERUSTIT passivation solution 2016, contact time 5-10 minutes
3. Fully demineralized water with a conductivity of 10 11m
70
VOITH
5.12 Connecting electrical instruments
Risk of injury
Dangerous electric currents and voltages on the

Geared variable speed coupling can injure or kill
individuals.
Only a qualified electrician who is knowledgeable

about rules that apply to electronic equipment in the
country of installation is allowed to perform work
involving the electrical equipment on the Geared
variable speed coupling.
Risk of injury
Hazard resulting from improper insulation.
As the result of improper insulation, an individual

could come into contact with electrical components
and be seriously injured.
Use only cables with insulation that can withstand the

ambient operating conditions!
Risk of Injury I equipment damage

Stray currents in the Geared variable speed coupling
can cause personal injury or damage gear teeth and
bearings.
Take suitable grounding measures on all components

of the drain train!
1. Connect all power consuming equipment.
2. Connect all control units.
3. Check motors for their direction of rotation, current draw and protection by fuses.
-+ Terminal diagram for wiring in the junction box.

-+ Chapter 14 "Attaching parts" of these Operating Instructions for detailed informa
tion on the instruments installed. 71
VOITM
5.13 Attaching guards
• Guarding to prevent accidental contact with rotating and hot components (connect- Types of guarding
ing couplings, oil lines) and other recognizable source of danger and protection
• Protection from noise
• Protection from the weather in the event of outdoor installation (roof or enclosure)
5.13.1 Attaching guarding to prevent contact
Risk of injury
Entanglement or trapping hazard in the vicinity of

rotating shafts and in the vicinity of the rotating
connecting couplings.
Clothing, long hair or loose objects (lines, cords and

ropes/cables) could become entangled in the danger
zone and cause serious injury / damage.
Attach suitable guarding over the connecting

couplings that can only be removed by using tools!
A CAUTION
Burn hazard
The housing, oil lines, connecting couplings and

working oil may be very hot - in extreme cases, up to
130°C. Contact can cause burns on the skin.
The Geared variable speed coupling must be allowed

to cool prior to maintenance or repair work!
Attach guarding to prevent contact with rotating and hot components and other recog
nizable sources of danger in compliance with the safety regulations of the operator
and/or the country where the equipment is being installed.
72
VOITM
5.13.2 Attaching sound-absorbing covers
Attach sound-absorbing covers in such a way as to not impede continued perfor Unimpeded work
mance of the following activities. 1
• Reading instruments on the instrument panel and on piping

• Reading the oil level from the oil level indicator
• Cleaning the duplex oil filter
• Actuating shutoff valves
• Installing and removing instruments
• Performing service work (topping up lubricant, e.g. in connecting couplings and the
like)
~t CAUTION
Explosion hazard
Heat may accumulate when using sound-absorbing

covers without openings.
Always provide sound-absorbing covers with vent

holes to dissipate the heat and exchange the air!
Poisoning hazard
Use of sound-absorbing covers without openings can

result in poisoning..
Poisoning and suffocation can result from gas leaks

when compressors are operating.
Always provide sound-absorbing covers with vent

holes to exchange the air!!
1. Instructions based on VOl Directive 2711 "Sound Protection by Encapsulation"

73
VOITM
• Avoid exposing instruments, control units, electrical insulation and equipment to Heat dissipation and
excessive operating temperatures. ventilation
• Provide separate ventilation for electric motors. The cooling air for an air-cooled
electric motor can be used for ventilation, if necessary (consider the characteristic
curve of the cooling fan and the required motor cooling).
• Regulate the air flow in the cover to ensure heat dissipation (determine the flow
rate for a cooling air temperature increase of 1DOC).
• Route the vented air from the gearbox housing and coverings (closed connecting
coupling covers) through the sound-absorbing covers via ducts.
• Provide openings and seals for shaft passages, windows for viewing of instru
ments, pipe and cable entry points and vents.
74
VOITM
5.14 Orifice holes for lube oil supply to external units
16 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5. 6.0

5.0 ~r=+rI......,-t--'1-1,,.-,-t ---It-I- IiI Y
I "'Iit- I
1 / -'---II-Ir--'--t-j-l/r-+-+-+(-k--r i
1--t-t-'+1- ~J.-+++,I-+,/+-++
1--t--tJ/~-t--/I-1I-t--'/h~-+-c/k---t---i6.5
"C
C
ca 4,0 +--I-t+f-t-r+-4--c- I V-- II
j -1/ /'I / I
J
1;
E
ca ...
G) ca
!::Jl
~.5
~ I
I G)
Curve from
iii .!:! equation:
;::
:e
c ...
G) 0
...G) 0
E I I /' Y ./ .. / ", V
Q=21 ,u*'P*d"( 1Ip/p1 v.
p = 840kg/nt
"C ca
~ ~ -- 110
~
en -------L=Pi
en
III
G) ;;0
... 0
e P1 ---I.
._._._---_.
D.."C o 10 20 30 40 50
Lube oil flow rate, ext. equipment in "min
10 12 14 16 18 20 22 25 27
" r-ll- I /i I ",I /
II 1~~+_,I,~-+I-h~~~~/~+-+-1
I II /
"C
C
ca
E
ca ...
G) ca
!::Jl
~.5
~ I
I G)
iii .!:!

;:t:::
c ...
G) 0
...G) 0
:e
"C ca
E
~ ~
~
en en I
III
G)
e
... 0
;;0
0,0 _ [J L " -I- ..L
D.."C
o 100 200 300 500 600 700 800 900 1000
Lube oil flow rate, ext. equipment in "min
75
VOITM
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M 6 Commissioning
6 Commissioning
Entanglement or trapping hazard in the vicinity of rotating shafts and in the vicin
ity of the rotating connecting couplings
Clothing, long hair or loose objects (lines, cords and ropes) could become entangled
in the danger zone and cause serious injury / damage.
Attach suitable guarding over the connecting couplings that can only be removed by
using tools!
Hazard from the hydraulics
Oil can escape from leaking connections or seals, create a slipping hazard and cause
injury as well as damage to the environment.
Clean up leaking oil immediately!
Escaping operating fluids could cause burns or injuries as well as damage to the en
vironment.
Wear of personal protective equipment, in particular, safety goggles when filling oil,
when checking for leaks and when changing filters!
Follow the procedures specified on the material safety data sheet for the particular
operating fluid!
Equipment damage
The Geared variable speed coupling is delivered without any oil in it. Operation wit
hout oil will damage the equipment within a few seconds.
CAUTION
Prior to sta.rtup, fill the Geared variable speed coupling with the working oil!
Note
Before starting the driving machine, check attaching parts (instruments, actuator, mo
tor etc.) for:
I OlE
Proper connection of the supply voltage, transmittal/processing of control and moni
toring signals.
76
VOITH
6.2 Fill the working oil
For Voith's list of recommended oils, see Section 6.7 "Operating fluids". The oil grades Criteria for suitable
contained in this list have been selected on the basis of the following criteria: working oil
• Lowest possible viscosity (Initial viscosity :0; 250 mm 2/s (cSt) at a temperature of
5°C)
• Superior lubricity
• Best possible air separation
• Resistance to aging
• Chemical neutrality with respect to metals and seals
• Compatibility with the human organism
If using an oil grade that does not appear in the recommended oil list: check
compatibility with Voith's corrosion-inhibiting oil (Shell Ensis Engine Oil 20).
Check the suitability of the oil on the basis of the criteria listed in Section 6.7
"Operating fluids". Clean the inside of the Geared variable speed
coupling. thoroughly.
For the required amount of oil, see Section 1.2 "Operating data" and the instructions
regarding the heat exchanger in Chapter 14 "Attaching parts" of this documentation.
". , .. IIII . . . "'~

>~:"'" "~:,., " ~~jj ~ Y",
Fill the working oil as soon the piping for the system has been completed.
1. Add oil at the flanged connection identified as "Oil filling" on the coupling's housing Filling oil
(see location of the ~ item in the assembly plan).
2. Filter the oil when filling (grade of filtration 25 ~m 1 or finer).
3. After the piping and coolers have been filled and bled, the oil level should be mid
enJ:
-b way between the min. and max. marks on the oil level indicator.
e.
'm
..:
"0
.§ Illustration 6-24:
~ Oil level indicator
"
~,
:;:OJ
MAX.
0
I
Max. mark
'"" Min. mark
'"0
0
0
~ x = Fill range
'"0
z
"
,2
1ij
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E
"8
c
1. Extends the life of the filter elements, especially during commissioning. Corresponds to an oil
"
.<:
~ cleanliness class of 18/15 as defined in ISO 4406. 77

VOITN
6.3 Flushing the coupling
The newly installed 011 lines must be flushed for several days prior to the actual com
missioning (corrosion protection and filtering of the oil).
1. Check the oil level (should be midway between the min. and max. marks on the 011 To be checked prior
level indicator). to flushing
2. Check and add lubricant for attached parts such as connecting couplings as nec
essary.
3. Check the direction of rotation of the auxiliary lube oil pump.
4. Check that threaded connections in the oil lines are oil tight.
5. Start the electrically operated auxiliary lube oil pump (lock out the driving machine Start the flushing
in case it would otherwise start automatically). operation
The lube oil circuit fills. The working oil circuit, the working oil cooler (when
mounted at a height the same as or below the 011 level) and the oil lines in the sys
tem are filled by an interconnecting line with orifice between the lube oil circuit and
working oil circuit.
6. Check the oil lines for leaks.
7. When the pressure differential increases to the max. permissible value
(Section 1.2 "Operating data"), switch the duplex oil filter to the cleaned filter hous
ing and clean the dirty filter housing (Section 8.4 "Cleaning the duplex oil filter").
8. Check the lube oil flow rate for external equipment and, if necessary, correct by Additional Items to
changing the size of the opening in the orifice plugs (Section "Drilling of orifices for be checked during
lube oil supplied to external units" on page 66). the flushing
operation
9. Check the amount of oil injected into the connecting coupling when working with
injection lubrication (manufacturer's specification) and, if necessary, correct by in
stalling orifice plugs.
1a.Check the oil level and, if necessary, add working oil (should be midway between
the min. and max. marks on the oil lever indicator).
11.Check the lube and control oil pressures and, if necessary, adjust at the pressure
relief valve for the lube oil and at the adjustable orifice (Section 6.5 "Adjusting the
lube oil and control oil pressures").
12.Check the operating points of the pressure measuring devices and, if necessary,
c correct.
",
~, 13.Flush the oil lines until the duplex oil filter remains clean (one to several days). Ending the flushing
§ operation
8CD",
CD 14.Switch off the auxiliary lube oil pump.
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VOITM
6.4 Trial run
6.4.1 Preparing for the trial run
1. Check the alignment of the coupling and correct as necessary. Items to be checked
and adjusted prior
2. Check attachment to the foundation.
to the trial run
3. Loosen connecting couplings and check the direction of rotation of the drive motor
with the Geared variable speed coupling uncoupled.
4. Check and add lubricant for attached parts such as connecting couplings as nec
essary.
5. Check for proper installation of connecting couplings and guarding.
6. Check that manufacturer specifications are met when adjusting the supply of lubri
cating oil to external equipment.
7. Check the oil level (should be midway between the min. and max. marks on the oil
level indicator).
8. Check for proper connection of the supply voltage to the electrical system as well
as transmittal/processing of signals.
9. When using water/oil coolers, open the valves on the water side, bleed the water
side of the oil cooler and check the flow rate.
Operating data (Section 1.2,2 "Heat exchanger" and instructions for the heat ex
changers in Chapter 14 "Attaching of this documentation.
Check the Voith electro-hydraulic positioning control (VEHS) only when the
auxiliary lube oil pump is operating. Inhibit automatic startup of the driving
machine.
1O.Check control (4-20 mA signal) and operation of the scoop tube positioning (0% to
100%) mechanism by the VEHS positioning control.
Instruction Manual for the Voith electro-hydraulic positioning control in Chapter 14
"Attaching parts" of this documentation.
11.Move the scoop tube to 0 % position.
12.Check that the entire system is ready to operate.
79
VOITN
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 M 6 Commissioning
6.4.2 Conducting the trial run
1. Start the auxiliary lube oil pump.
2. When the lube oil pressure reaches the required value, switch on the driving ma
chine or monitor automatic startup.
3. Once the driving machine is up to speed and the required lube oil pressure has
been reached, monitor automatic shutdown of the auxiliary lube oil pump or switch
off the pump manually.
4. Operate the system at minimum speed. Minimum speed
5. Monitor smooth operation, temperatures lube oil pressure and filter condition.
6. Slowly increase the speed of the driven machine. Increase the speed
slowly
7. Monitor and log temperatures and pressure until they stabilize.
8. Check for proper operation of the temperature controls (if installed) at the lube oil
heat exchanger (Instruction Manual for heat exchangers in Chapter 14 "Attaching
parts" of this documentation).
9. If the hubs for the connecting couplings have not been provided and balancing of
the complete arrangement was performed without original hubs: rebalance the in
put and output shafts if the eqUipment does not operate perfectly smoothly.
1O.Measure the vibration. Evaluate whether the equipment is operating smoothly and
log the scoop tube position, speed and reading at measurements points.
11.lf the working oil temperature becomes too high, correct the working oil flow rate
by means of the lever arrangement for the "oil circulation valve position adjust
ment" (Section 6.6 "Adjusting the working oil flow rate").
If the characteristic of the system is to be optimized on the basis of the operating con Operating over the
ditions: entire speed range
12.0perate the system over its entire speed range.
13.Adjust the lever arrangement for the "oil circulation valve angle adjustment"
(Section 6.6 "Adjusting the working oil flow rate").
14.Slow the system down to minimum speed. Slowdown
15.After switching of the driving machine, check that the auxiliary lube oil pump
switches on automatically.
16.0nce the driving machine and the driven machine have come to a stop, switch off
the auxiliary lube oil pump.
80
VOITH
17.Clean the duplex oil filter as necessary and fill with working oil (Section 8.4 After the trial run
ing the duplex oil filter").
If the lube oil cooler is mounted at a height the same as or above that of the duplex
oil filter, switch to the other filter housing beforehand (Section "Changing over the
filter" on page 95).
18.Check the oil level and correct (should be midway between the min. and max.
marks on the oil level indicator).
19.Check the piping for leaks.
81
VOITH
6.5 Adjusting the lube oil and control oil pressures
Adjust the oil pressures only at operating temperature!
The lube oil and control oil pressures are adjusted at the pressure relief valve and at
the adjustable orifice. The lube oil and control 011 pressures are not adjusted separa
tely; they affect one another. For pressure values, see Section 1.2 "Operating data".
Illustration 6-25:
"Lube oil" pressure relief
valve
Pressure relief valve

( 2 Housing
3 Adjusting screw
4 Screw plug
Burn hazard
Hot oil under high pressure can cause serious burns.
Do not unscrew the adjusting screw (3) out of the

housing completely!
1. Unscrew the screw plug (4). Making adjust

ments at the
2. Screw in the adjusting screw (3).
pressure relief
3. Check the pressure increase at the pressure gauge and correct as necessary: valve (1)
- Turning the adjusting screw clockwise: Increases the lube oil and control oil
pressure
- Turning the adjusting screw counterclockwise: Reduces the lube oil and control
oil pressure
4. Check the control oil pressure on the control oil pressure gauge and, if necessary,
correct with the aid of the adjustable orifice.
5. Install the screw plug (4) and seal ring.
82
VOITH
Illustration 6-26:
Adjustable orifice
1 Orifice plug
2 Protective cap
3 Check nut
4 Adjusting screw
5 Seal ring
x = Parts of the ad

justable orifice
1. Unscrew the protective cap (2). Adjusting by means

of the adjustable
2. Loosen the check nut (3).
orifice (1)
3. Check the pressure increase at the control oil and lube oil pressure gauge and cor
rect: as necessary.
Turning the adjusting screw clockwise: Increases the control oil pressure, re
duces the lube oil pressure
- Turning the adjusting screw clockwise: Reduces the control oil pressure, in
creases the lube oil pressure
4. Tighten the check nut (3).
5. Install the screw plug (2) and seal ring.
(jj
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VOITM
Voith Turbo I Geared variable speed coupling I SEC 56 Indonesia Pelabuhan I R 15 K 400 M 6 Commissioning
6.6 Adjusting the working oil flow rate
The positioning control unit is controlled by a 4-20 mA signal from the process cont Positioning unitwlth
roller. It provides control of the scoop tube and the circulation valve. The circulation positioning control
valve and scoop tube are connected by a lever system. The lever system is adjus unit
table.
The oil circulation valve is used to reintroduce to the coupling the amount of oil that 011 circulation
must be diverted to remove the heat generated as a result of the power loss. The oil control
flow rate is set at the factory to the value obtained from the power loss calculations.
If overly high or overly low temperatures occur at certain operating points, the working
oil flow rate can be changed via the oil circulation valve. The oil circulation valve is
controlled by the kinematics of the lever system as a function of the scoop tube posi
tion. By making modifications to the lever system, the piston stroke and the associa
tion to the scoop tube position can be Changed.
Risk of Injury
Risk of moving parts crushing or shearing the upper

and lower body limbs.
A person's finger could be crushed or sheared by the

motion of the positioning mechanism.
Allow only trained personnel to perform assembly,

maintenance and service workl
Equipment damage
Unauthorized readjustment can result in mechanical

damage to the oil circulation valve.
The following description must be observed when

adjusting the oil circulation valve!
84
VOITH
Range of adjustment of the oil circulation valve:
Illustration 6-27:
Oil circulation valve
indicator
a Indication range at
an angle of a = 180·
b Indication range over
the entire scoop tube
stroke range
In the event of a high or low oil temperature over the entire speed range or scoop tube High or low oil
position range, the oil flow rate can be increased or reduced: temperature over
the entire speed
range
Illustration 6-28:
Lever system for oil
circulation valve
Check nut
2 Set screw
3 Nut
a Permissible range of
adjustment when
angle a = 180 0
c Pointer
85
VOITM
NOTE
Make adjustments only when angle a = 180°. Pointer (c) of the piston position
indicator must be within the range of adjustment (a).
1. Loosen check nut (1) and unscrew slightly.
2. Adjust the threaded spindle by means of the nuts (3).

- Counterclockwise rotation (increase in oil flow rate)
- Clockwise rotation (reduction in oil flow rate)
3. Turn check nuts (1) to stops and tighten.
In the event of a high oil temperature in a certain speed range or scoop tube position High 011 temperature
range, the max. control point of the level system can be associated with the corres In a certain speed
ponding scoop tube position: range
I/Iustration 6-29:
Lever arrangement for
oil circulation valve
angle association
4 Adjusting lever
5 Clamping screw
d Scoop tube stroke

indicator
e Radius indication for
lever position
Angular position
scale
1. Bring the scoop tube into the position with the max. oil temperature.
iii
2. Read off and document the scoop tube position in % on the scoop tube indicator (d).
!
'ij
3. Read off the radius indication (e) on the adjusting lever (4) and always maintain
when making other adjustments.
c
"', Read off and document the angular position of the adjusting lever (4) on the
~ scale (f). Loosen the clamping screws (5) slightly.
0'
~ 4. Rotate the adjusting lever (4) until the angular position on the scale (f) matches the
~"'~~ scoop tube position in %. After this, angle a must be 180°. Tighten the clamping
~~ screws (5) .
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~~ 86
VOITM
6.7 Operating fluids
The following can be used, provided they satisfy the requirements:

Grade selection by
operator and 011
Hydraulic oils HLP 32 as specified in DIN 51524, Part 2
supplier
Do not mix different oil grades. Approval to use oil mixtures must be clarified with the
oil supplier.
Requirements (characteristics) of the operating fluids and recommended grades:
~ Appendix_B_ "Operating fluids ISO VG 32 for hydrodynamic circuits with gearing
3625-006073"
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VOITH
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M 7 Operation
7 Operation
Hazard from unseen areas
An individual could be seriously injured while handling the equipment if it starts up un
expectedly.
Attach suitable guarding between the coupling and shaft that can only be removed by
using tools!
Work on the equipment only after the power has been disconnected (no voltage pre
sent)!
Entanglement or trapping hazard In the vicinity of rotating shafts and in the vicin
Ity of the rotating connecting couplings
Clothing, long hair or loose objects (lines, cords and ropes/cables) could become ent
angled in the danger zone and cause serious injury / damage.
Attach suitable guarding over the connecting couplings that can only be removed by
using tools!
In the event of severe imbalance, a shaft could break as the result of vibrations and
cause serious injury or damage to the equipment.
If the imbalance is impermissibly high or the equipment is not running smoothly, con
duct an inspection immediately!
Slipping hazard due to leaking oil
Leaking oil could cause someone to slip on or next to the equipment or fall and be se
riously injured.
Check for leaking oil or leaks on a regular basis!
Clean the equipment regularly!
c
", Hazard from the hydraulics
~,
c;; Oil can escape from leaking connections or seals, create a slipping hazard and cause
S
o injury.
Ocr>
:!!fri
~i Clean up leaking oil immediatelyl
.§ s
OJ'"
1:fri
~re
8~
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~c1l 88
VOITH
Voith Turbo I Geared variable speed coupling I SEC 56 Indonesia Pelabuhan I R 15 K 400 M 7 Operation
Fire hazard
In conjunction with high temperatures and oil, an electrical short circuit due to an ab
raded cable or water leaking into the junction box could trigger a fire and cause per
sonal injury or damage to the environment.
Allow only a qualified electrician to install the equipment!

Observe the maintenance intervals!
Fire hazard
Leaking (hot) oil or oil mist could trigger a fire and cause serious injury.
Hazard from improper Installation
Equipment rotating in the wrong direction could self-destruct and cause serious injury.
Improper installation of the equipment or its components could result in destruction of
the equipment.
Allow only trained personnel to perform assembly, maintenance and service work!
Hazard from pressure shocks, pressure rise or pressure loss
Pressure shocks can cause vibration and pipe failure, and result in personal injury due
to leaking oil. I. CAUTION
Ensure that the installation complies with the designated use of the equipment and
that the operating data and ambient conditions are taken into account!
Noise hazard
A sustained sound pressure level above 85 dBA could lead to loss of hearing.
Wear hearing protection!
I. CAUTION
Environmental pollution
Leaking oil could damage the environment.
CAUTION
89
VOITM
7.2 Starting up and shutting down the equipment
Equipment damage
The Geared variable speed coupling is delivered

without any oil in it. Operation without oil will damage
the equipment within a few seconds.
Prior to startup, fill the Geared variable speed

coupling with the working oil!
1. Check the same items that were checked prior to the trial run (Section "Items to be Checks prior to
checked and adjusted prior to the trial run" on page 79). startup
2. Check that the entire system is ready to operate.
3. Place the scoop tube in the 0 % position.
The Geared variable speed coupling can, in principle, be started up with the scoop
tube in any position. However, starting up with the scoop tube in the 0 % position
is preferred, since the driving machine can come up to speed with practically no
load.
Startup
Operating conditions Action Result
Bring the oil temperature Start enabled

in the reservoir up to ~ 5°C; heat, if
necessary
Place the scoop tube in the 0 % posi

tion.
Switch the aux. lube oil pump ON The coupling and driven machine are at
standstill.
Bearings are being lubricated
At a lube oil pressure> 1.7 bar: Switch the driving machine ON Driving machine starts up.
Iii Coupling fills and starts to rotate.
i
"iii 3 min. after starting the driving machine Switch the aux. oil lube pump OFF Coupling and driven machine are oper
and at a lube oil pressure of 2.2 bar: ating.
Place the scoop tube in the n % posi Driven machine is operating at the de
tion. sired speed.
Shutdown
Place the scoop tube in the 0 % posi Coupling empties.

tion. Driven machine is operating at mini
mum speed.
90
VOITM
Shutdown
Switch driving machine OFF Driving and driven machines come to a

stop.
Bearings continue to be lubricated.
Automatically when driving machine is Aux. lube oil pump switches ON Bearings continue to be lubricated.
switched OFF or when lube oil pressure
< 1.5 bar:

After equipment comes to a stop Switch the aux. oil lube pump OFF Bearings are no longer lubricated.
7.3 Operating the equipment
7.3.1 Monitoring the equipment
The following items must be monitored during operation:
• Temperatures
• Lube oil pressure
• Pressure differential (oil filter)
• Oil level
NOTE
If the behavior of the Geared variable speed coupling changes during
operation, this indicates the need for service. Section 8.2.2 "Service/repair
measures and intervals".
Temperatures
011 reservoir
Temperature of oil in the reservoir Operating range 1 > 45 - < 65°C
Alarm at 1 70 °C
Shutdown at 1 75°C
1. Indication or signal only with appropriate instrumentation
Bearings
Bearing temperatures Operating range
Alarm at
Shutdown at
The bearings can have different temperatures. Reasons:
• Different shaft speeds

• Different bearing loads
91
VOITM
• Heat load from working oil
Set trigger point for the message "Bearing temperature too high" to about 15°C above
the temperature of the warmest bearing or to ,,90°C".
Working oil
Working oil temperature Operating range > 60 < 110 DC
upstream of the heat exchanger Alarm at 1 110 DC
Shutdown at 130 DC
Working oil temperature Operating range > 35 < 75 DC
downstream of the cooler Alarm at 2 75 DC
Shutdown at2 85 DC
1. Temperatures above 110°C do not occur during normal operation, but only when flushing or
performing a similar activity.
Lube oil
Lube oil temperature Operating range > 45 < 65 DC
upstream of the cooler Alarm at 1 65 DC
Shutdown at 1 70 DC
Lube oil temperature Operating range > 35 < 55 DC
downstream of the heat exchanger Alarm at 55 DC
Shutdown at 60 DC
The fusible plugs melt when the working oil temperature in the scoop chamber rea Fusible plugs
ches 160°C 1 , thus preventing overheating of the coupling.
Reasons for a brief increase in working oil temperature could be:
• lack of cooling (cooler malfunction)
• overloading of the coupling
Fusible plugs that have melted result in the following:
slight change in the control behavior of the coupling
almost max. power output
slight increase of the oil temperature in the reservoir
~ longer time for the driven machine to come up to speed

!
"ij
1. if the necessary oil temperature acts on the solder in the fusible plug together with a suitable oil
pressure.
92
VOITM
Voith Turbo I Geared variable speed coupling I SEC S61ndonesia Pelabuhan I R 15 K 400 M 7 Operation
Pressures
Working oil/lube
Working oil pump pressure 1.5 to 2.5 bar oil/control 011
Test connection M1 (assembly plan)
Working oil pressure upstream of the oil circulation valve 1 1.3 to 2.3 bar
Working oil pressure downstream of the scoop tube max. 3.0 bar
Lube oil pressure Operating range 2 2.5 + 1.0 bar
Switch on driving mach. at t 1.7 bar
Shutdown of the auxil. lube oil pump at3 t 2.2 bar
Alarm - auxil. lube oil pump ON at J. 1.5 bar
Shutdown of driving mach. at J. 0.8 bar
Control oil pressure Operating range 4 3.0 to 4.0 bar
Test connection M4

3. after a duration of 3 minutes
The working oil pressure upstream of the all circulation valve is maintained within the
operating range by the pressure relief valve. lube oil and control oil pressure:
Section 6.5 "Adjusting the lube oil and control oil pressures".
011 level
After the piping and coolers have been filled, the oil level should be midway between
the mln.- and max..marks on the oil lever indicator.
til
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VOITH
7.3.2 Controlling the speed
The scoop tube is shifted between the 0% and 100% positions by the Voith electro
hydraulic positioning control (VEHS). The scoop tube position determines the speed
of the driven machine.
The Voith electro-hydraulic positioning control (VEHS) is positioned on the basis of a Automatic control
control signal of 0 or 4-20 mA from a master controller.
Linearization of a non-linear positioning control. Linearization unit
In the event of a problem with the position setpoint from the master controller, opera Monitoring of the
tion switches to local control. The last position is retained as long as there are no load Wposltion setpolnt
changes.
-+ Chapter 14 "Attaching parts" of this Instruction Manual provides detailed descrip

tions of the VEHS and the auxiliary device.
7.3.3 Changing over the duplex oil filter
Pressure differential across duplex oil Switch and clean filter at > 0.8 bar
filter
The duplex oil filter cleans the lube oil. It has two filtering jugs, through only one of
which oil flows during operation. The filter is equipped with a differential pressure
switch that triggers an alarm when the pressure differential across the filter becomes
too large. The alarm indicates that the specified pressure differential has been excee
ded. The filter element currently in use has thus reached a certain degree of contami
nation and must be cleaned (Section 8.4 "Cleaning the duplex oil filter" on page 105).
NOTE
Contaminated versus clean filtering jug indicated by position of change-over
lever. The position indicator indicates the filtering jug that is currently in use.
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VOITM
Voith Turbo I Geared variable speed coupling I SEC 56 Indonesia Pelabuhan I R 15 K 400 M 7 Operation
Illustration 7-30:
Allocation of filtering jug
to the position indicator
Filtering jug in use

2 Filtering jug to be
cleaned
3 Flow indicator and
position indicator
4 Vent valve
5 Drain valve
6 Plug
7 Pressure equaliza
tion valve
Before the duplex oil filter can be switched to the clean filtering jug, this housing must Flooding the clean
first be flooded. filtering jug
NOTE
If the clean filtering jug is not flooded, the lube oil pressure drops too drastically
upon switching the duplex oil filter, and the system is shut down by the
monitoring instruments.
Putting the filtering jug into operation:
1. Remove the plug. Place a container under the vent line. Open the vent valve
slightly.
2. Open the pressure equalization valve and flood the clean filtering jug until oil ap
pears at the vent line. Close the pressure equalization valve.
3. Close the vent valve. Install the plug.
The clean filtering jug is now ready for operation.
cii 4. Using the change-over lever, slowly switch the filter to the clean filtering jug. Changing over the
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7.4 Measures to take in the event of tailspin and rotation in the

opposite direction
The term "tailspin" describes the slow rotation of the coupling caused by the driven Tailspin
machine after the system has been shut down, e.g. by a fan drive.
• Switch on the auxiliary lube oil pump to ensure that the bearings are lubricated.
If the driven machine can cause rotation in the opposite direction, a device to monitor Rotation of the
the direction of rotation must be provided. If this rotation monitoring device signals ro secondary shaft in
tation in the opposite direction: the opposite
direction
• Switch on the auxiliary lube oil pump without delay.
• Set the scoop tube to the 100 % position.
• Close the shutoff valve on the driven machine.
• Limit rotation in the opposite direction to max. 1-3 minutes.
NOTE
Check the Geared variable speed coupling after the driven machine has rotated
in the opposite direction. Inspect the bearings for signs of overheating. Check
the fusible plugs. Switch on the auxiliary lube oil pump and check the oil
pressures.
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7.5 Taking a sample of the working oil
NOTE
The value of the information obtained from an analysis of the working oil
depends on correct and careful sampling. An oil sample is preferably taken from
a region with good flow of oil either during operation or immediately after a
system shutdown.
In the case of the Geared variable speed coupling, the oil sample should be taken
from the lube oil circuit. A reliable oil sample can be drawn from the filtering jug cur
rently in operation.
Burn hazard
The filtering jug, oil lines and working oil can be hot. In
an extreme case, up to 60°C for this section of the
lube oil circuit.
Wear protective glovesl
Risk of Injury
Hot, pressurized oil in the duplex oil filter and vent line
can cause serious injury.
Wear protective gloves, safety goggles and protective

clothingl
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Used oil that escapes into the sailor sewage system


97
VOITM
Voith Turbo I Geared variable speed coupling I SEC S61ndonesia Pelabuhan I R 15 K 400 M 7 Operation
• Collection container for initial amount drawn Aids

• Sample collection container(s)
1. Identify the active filtering jug. The selector handle indicates the filtering jug that is Taking the oil
currently in use Illustration 7-30 "Allocation of filtering jug to the position indicator" on sample
page 95.
NOTE
Perform the remaining operations only on the filtering jug currently in use. The
oil sample must only be taken from the clean oil side (filter cover).
2. Remove the plug from the vent valve.
NOTE
If the vent valve is opened too far, a pressure drop could result, causing the
monitoring instruments to shut down the system.
3. Place the collection container for the initial amount beneath the valve and open the
vent valve slightly.
4. After drawing off some initial oil, fill the oil sample container with working oil.
5. Close the vent valve and reinsert the plug.
7.6 Measures to take during standby
• Allow the auxiliary lube oil pump to run continuously.
7.7 Measures to take during stop periods
When the stop periods are longer than a day:
• Switch on the auxiliary lube oil pump for at least five minutes daily.
.~ • Protect the Geared variable speed coupling against ingress of water and moisture.
~
Apply corrosion inhibitor to bare metal parts.
~
• Start up the Geared variable speed coupling briefly every 1-2 months. Do not al
;1 low to operate until warm (risk of condensation forming).
~
i co The internal surfaces of the eqUipment receive a light film of oil and are thus protected
c;;~
against corrosion.
~~
.§.9 For idles times of heat exchangers: see the operating instructions for heat exchangers
....
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in Chapter 14 "Attaching parts" of this documentation .
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VOITM
7.8 Removing the Geared variable speed coupling
Risk of Injury
Dangerous electric currents, voltages and other

sources of energy on the Geared variable speed
coupling can injure or kill a person.
Before removing the Geared variable speed coupling,

disconnect every external source of energy. Drain all
liquids.
The Geared variable speed coupling must be

removed only by qualified personnel who perform
their work in compliance with local safety
requirements.
Used oil that escapes into the soil or sewage system


Prior to disassembly for salvage purposes or scrapping, completely remove any oil or
other substances that pose a danger to water.
The Geared variable speed coupling is made of steel, lightweight alloys and various
plastics. These materials can be salvaged and recycled.
Send problem materials that can no longer be used to an authorized disposal facility.
99
YOITM
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 M 8 Maintenance
8 Maintenance
Hazard from ejected parts
Without the connecting coupling and guarding attached, the feather key or bolts from
the connecting coupling could be ejected and injure someone.
Allow only trained personnel to perform installation, maintenance and service work!
The variable speed coupling must be started up only after the connecting coupling is
attached (as a minimum) or the complete connecting coupling and protective guarding
in accordance with the manufacturer's instructions.
Hazard from an incompletely shut down and secured system
A system that has not been shut down completely and secured could restart and in
jure anyone working on the equipment.
Work on the equipment only after the power has been disconnected from the system
(no voltage present)!
Hazard from invisible areas
A person handling the equipment could be injured seriously if it starts up.
Attach only appropriate guarding that requires tools to remove between the coupling
and shaft!
Work on the equipment only after the power has been disconnected from the system
(no voltage present)!
Burn hazard
A person could be burned by touching a hot machine or coming into contact with hot
operating fluids.
Touch the machine only after it has cooled down!
Risk of being cut
A person could be cut by sheet metal guarding that has not been deburred or by sharp
edges on an enclosure. I.CAUTIOtt.1
100
VOITN
Voith Turbo I Geared variable speed coupling I SEC 56 Indonesia Pelabuhan I R 15 K 400 M 8 Maintenance
Escaping operating fluids could cause burns or injuries as well as damage to the en
vironment.
Wear personal protective equipment, in particular, safety goggles when filling oil,
when checking for leaks and when changing filtersl
Follow the procedures specified on the material safety data sheet for the particular
operating fluid!
Risk of Injury
The wrong seals or improperly sealed metal surfaces, flanges, inadequately tightened
joints or incorrectly set pressure relief valves could allow oil to escape and cause per
sonal injury.
Note
Keep access paths to areas needed for service work free of obstructions. Ensure
compliance with dimensions and placement shown in the installation diagram!
NOTE
101
VOITM
8.2 Maintenance and repair
• Maintenance, measures to take to maintain the desired condition

• Repair, measures to take to restore the desired condition.
8.2.1 Maintenance measures and intervals
When the equipment is operating

If the pressure differential across the duplex oil filter in
Switch and service the duplex oil filter
creases
If the speed of the driven machine fluctuates Check the air separation characteristics of the working
oil.
Ensure that the working oil cooler is venting continu
ously.
If the oil level is high Check the amount of water in the working oil l .
Daily, if monitoring of the instruments is not incorporated into • Check the oil level.
a supervisory system
Every three months Check vent filter for external soiling and clean as neces
sary.
Always check for smooth operation under the same oper

ating conditions 2 , record and compare the measure
ments.
Check that the working oil 1+3 is suitable for use.
1. Section 8.5 "Test criteria and notes lor evaluating working oils"
2. Specification of measurement points within the output speed range.
3. This maintenance interval can be extended, depending on experience with the equipment. This should not exceed 6 months.
When the equipment is idle

If the oil quality is questionable (suitability for use) Determine and correct the causes. Separate or ex
change the oil l .
The vibrations have increased Check and correct alignment of the Geared variable
speed coupling. Check attachment to the foundation.
Between 50 and 500 hours of operation Examine the gear teeth surfaces for signs of scuffing.
After every 8,000 hours of operation or at least annually • Analyze the working oil for signs of ageing; take any nec
essary measures 1.
Inspect and service the connecting couplings 2 •
Check and service the motor3 for the auxiliary lube oil
pump.
• Check and correct alignment of the Geared variable
speed coupling. Check attachment to the foundation.
• Open the inspection hole cover on the housing cover and
check the gears and coupling from the outside. In partic
ular, check the contact pattern on the tooth flanks and
the state of the fusible plugs (solder filling).
1. Observe the specifications of the oil supplier

2. Note the manufacturer's specifications and identification marks regarding balancing
3. Observe the manufacturer's specifications
102
VOITM
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M 8 Maintenance
NOTE
Prior to restarting a Geared variable speed coupling check bearings for signs of
overheating that was shutdown for some reason, inspect the fusible plugs,
switch on the auxiliary lube oil pump and check the oil pressure.
8.2.2 Service/repair measures and intervals
Change in operating behavior Determine cause.

Repair the Geared variable speed coupling.
After max. 8 years of operation Perform a general overhaul.
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8.3 Cross references
Topics
Relevant documentation
Working oil
Section 6.2 .Fill the working oil"
Section 6.7 "Operating fluids"
Section 8.5 "Test criteria and noles for evaluating working oils"
Oil supplier's specifications
Fusible plugs
Section 8.6 "Replacing the fusibie plugs"
Duplex filter
Section 7.3.3 "Changing over the duplex oil filter" and Section 8.4 "Cleaning the du
plex oil filter"
Working oil cooler: Section 5.11.5 "Installing the vent lines"
Operating instructions for heat exchanger in 14 "Attaching parts" of this
documentation
Alignment Section 5.9 "Machine alignment"
Temperatures and pressures Section 7.3.1 "Monitoring the equipment"
Connecting couplings Manufacturer's specifications
Auxiliary lube oil pump motor Manufacturer's specifications
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8.4 Cleaning the duplex oil filter
• Cleaning container with clean mineral spirits of diesel oil (approx. 10 I) Aids
• Container to collect draining oil (approx. 20 I)
• Brush
• Compressed air
Burn hazard
The filter housing, oil lines and working oil can be hot.
In an extreme case, up to 60°C for this section of the
lube oil circuit.
Wear protective gloves!
Risk of injury
Hot, pressurized oil in the duplex oil filter and vent

(bleeder) line can cause serious injury.
Wear protective gloves, safety goggles and protective

clothing!
CAUTION
Used 011 that escapes into the soil or sewage system


105
VOITM
Illustration 8-31:
Duplex filter
Selector handle
2 Vent alva
3 Oil drain valve
4 Plug
5 Plug
1. Determine the filter housing currently in use and the one to be cleaned. Note the Draining 011
"Flow mark I indicator" beneath the selector handle (1).
NOTE
Perform the following operations only on the filter housing to be cleaned.
2. Remove the screw plugs (4 + 5).
3. First open the oil drain valve (3) and then the vent valve (2) on the dirty filter hous
ing and collect the draining oil in a suitable container.
NOTE
Do not switch filters while cleaning, and do not open the pressure equalization
valve.
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Illustration 8-32:
Filter housing with filter
insert
Filter cover
2 Filter insert
open at one end
3 Filter housing
4 O-ring
4. Unscrew the filter cover (1). Removing the filter

insert
5. Remove the filter insert (2).
- Inside of the filter insert: clean oil side
- Outside of the filter insert: dirty side
6. Clean the inside of the filter housing (3).
7. Clean the outside of the filter insert (2) with mineral spirits or diesel oil; wash the Cleaning the filter
outside of the filter from top to bottom with the aid of the brush. Do not immerse the insert
filter insert in the cleaning fluid.
8. Using compressed air, blowout the filter insert from the inside toward the outside.
9. If the filter insert is heavily soiled, repeat the cleaning procedure.
1O.lf particles from seals or gaskets are observed in the filter insert (stainless steel
mesh), immerse the insert briefly (max. 15 min.) in trichloroethylene or a substi
tute and wash off.
11.lnspect the filter insert and a-rings for damage.
12.Place the filter insert (2) in the filter housing (3). Make sure that the a-rings are po- Reinstalling the
sitioned properly. filter insert
13.Attach the filter cover (1). Close the 011 drain valve and the vent valve. Screw in the
screw plugs.
14.FiII the filter housing with oil (Section "Flooding the clean filtering jug" on page 95).
107
VOITM
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 M 8 Maintenance
8.5 Test criteria and notes for evaluating working oils
The suitability of working oils for continued use should be checked and evaluated at
General
regular intervals.
The value of the information obtained from an analysis of the working oil depends on
correct and careful sampling Section 7.5 "Taking a sample of the working oil".
NOTE
This list contains aspects to be considered and rough limits for evaluating the
suitability of working oils for continued use.
The decision regarding the suitability of the working oil for continued use
remains the right of the manufacturer and oil supplier.
The following can only be considered recommendations, since they depend on the
operating conditions, formulation and type of working 011.
The oil should be changed when
• It is very black in color Visual and sensory

• Residues start to accumulate check
• It has a sharp, burnt odor
It is necessary to determine the cause.
• Viscosity change> ± 10% Viscosity

(DIN 51562)
It is necessary to determine the cause.
• Increase in NZ(s) versus that of fresh oil (new working oil) Neutralization number
NZ(s) (DIN 51558)
- Turbine oil -TD-O.S -1 mg KOH / g
- Hydraulic oil -HLP-1 - 1.5 mg KOH / 9
- Lube oil -CLP-1.5 - 2 mg KOH / g
• Water content> 0.05 weight % (500 ppm). Water content

(DIN 51582)
No 011 change is necessary, if the water content is eliminated by means of
Centrifuging
I::
o Filtering through a coalescence separator
"f:2
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"", Settling (allowing to rest for 1-2 days) and then draining or pumping off 1
~, - Heating
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An oil change Is necessary when
• Water content is > 0.2 weight %

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~ It is necessary to determine the cause.

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~" 108
VOITH
• Occurrence of pressure and speed fluctuations, if too Iowan oil level is to be ex Air separation
cluded and the LAV value > 5 minutes (0.2% at 50°C). characteristics LVA
(DIN 51381)
• Reduction in FZG load level, if it drops more than one level. Damaging force
(remaining additive content of EP components < 30%) level In FZG test
Al8,3/90
(DIN 51354)
"iii
109
VOITM
8.6 Replacing the fusible plugs
Illustration 8-33:
Location of the fusible
plug
Primary wheel
•
\® 2 Shell
3
a
Fusible plug
Inspection port cover

-$- -6--$
b Output
1. Remove the inspection hole cover on the housing cover.
2. Rotate the input shaft until the fusible plugs (or the holes for the fusible plugs) in
the shell are visible.
3. Check the solder filling in the plugs; install new plugs, if necessary.
110
VOITM
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M 9 Troubleshooting
9 Troubleshooting
9.1 Startup
Malfunction Cause(s) Action(s)
Driven machine does not • Scoop tube set at 0 % Take the following actions:
start up after the driving
machine has attained its Move scoop tube towards 100 %

rated speed Check the supply voltage for the scoop
tube actuator
Check to positioning signal
Troubleshooting
Section 14,6 "Voith electra-hydraulic po
sition control unit"
Check the control oil pressure
Working oil pump does not deliver oil Take the following actions:
Oil temperature of reservoir < +5 °C or Warm oil to > +5 °C, possibly by run
oil Viscosity ~ 250 mm 2/s ning the pump. Close the cooling water
supply on the lube oil cooler
Oil level too low Check the oil level and fill to between
the min. and max. marks. Check the fu
sible plugs.
Foaming oil (oil temp. too low; water in Check to oil for contaminants. Centri
the oil; poor air separation characteris fuge or separate the oil Change all, if
tics; wrong oil grade) necessary
Working oil pump pressure < 1.0 bar Check the work oil pump pressure at at
pressu re test ports
Working oil delivery rate too low Increase the working oil flow rate at the
• Startup torque too high (high motor inrush • Check that driven machine turns freely.
current), driven machine blocked (see Check fusible plugs
working oil temperature)
111
VOITM
9.2 Output speed
Autom. I Manual Foaming oil (oil temperature in reservoir Warm oil in the reservoir to > 40 cC. To do
control: < 40 cC, resulting in poor air separation so, lower the cooling water flow rate by par
characteristics) tially closing the cooling water inlet valve
Output speed fluctu on the lube oil cooler.
ates
Working oil pump pressure fluctuates Take the following actions:
Actuator and scoop
tube do not move Oil temperature in reservoir < 40 cC, re Warm 011 in the reservoir to > 40 cC. To
sulting in poor air separation character do so, lower the cooling water flow rate
istics by partially closing the cooling water in
let valve on the lube oil cooler
sible plugs.
Foaming oil (oil temp. too low; water in Check the oil for contaminants. Centri
the oil; poor air separation characteris fuge or separate the oil Change oil, if
pressure test ports
Air trapped in working oil cooler escaping Check that cooler is vently completely (the
periodically into coupling working oil cooler must be vented at three
locations on the shell)
Pressure or flow rate variations in the water • Check the water supply system
supply system (in the case of a pump-oper
ated supply)
Output speed cannot be Malfunction in master control circuit or with • Check the positioning control unit and con
controlled the actuator trol circuit (electr. connections)
Control oil pressure too low • Readjust the control oil pressure; also
check the lube oil pressure and readjust as
necessary
Problem in the scoop tube actuator Check that the scoop tube moves freely
Max. output speed not at-· Scoop tube not at 100 % Check the scoop tube position at the scoop
tained tube stroke indicator. Troubleshooting
Section 14.6 ,Voith electro-hydraulic posi
tion control unit"
Check the control oil pressure.
Fusible plugs have melted Determine and correct cause. Install new
fusible plugs.
Power consumption of the working oil Check the motor rating with the project de
pump too high sign data. Check that driven machine turns
freely.
• Working oil flow rate too low Readjust the working oil flow rate
112
VOITN
9.3 Pressures
Malfunction Cause(s) Actlon(s)
Lube 011 pressure too low • Motor for auxiliary lube oil pump connected • Check line connections
to enable startup incorrectly
• Delivery of lube oil to external equipment • Adjust orifices

too high
• Leak in the oil circuits • Check the oil level.

Check the piping for leaks (take the neces
sary action to prevent damage to the envi
ronment).
• Pressure relief valve set too low • Correct the pressure relief valve setting
• Lube oil filter clogged • Switch lube oil filters and clean filter hous
ing.
Check pressure differential monitoring.
Pressure differential • Lube oil filter clogged Switch lube oil filters and clean filter hous
across duplex filter too ing.
high
Lube oil pressure too low • Lube oil filter clogged • Switch lube oil filters and clean filter hous
during normal operation ing.
• Pressure relief valve jammed or set incor • Check the pressure relief valve; readjust
rectly lube oil pressure as necessary.
• Delivery of lube oil to external equipment • Adjust orifices

too high
• Check valve in auxiliary lube oil pump cir Check the check valve
cuit jammed (motor for auxiliary lube oil
pump rotating in the wrong direction)
Working oil pump pres • 011 temperature in reservoir < 40 DC, result • Warm oil in the reservoir to > 40 DC. To do
sure too low ing in poor air separation characteristics so, lower the cooling water flow rate by par
tially closing the cooling water inlet valve
on the lube oil cooler
Oil level too low • Check the oil level and fill to between the
min. and max. marks. Check fusible plugs.
• Mechanical wear • Check the pump
• Foaming oil (011 temp. too low; water in the • Check to oil for contaminants. Centrifuge or
i
'iii
oil; poor air separation characteristics;
wrong oil grade)
separate the oil Change oil, if necessary
113
VOITN
Voith Turbo I Geared variable speed coupling I SEC S61ndonesia Pelabuhan I R 15 K 400 M 9 Troubleshooting
9.4 Temperatures
Lube 011 temperature • Lube oil heat exchanger:

downstream of lube oil
heat exchanger too high Cooling water flow rate too low • Increase the cooling water flow rate
Cooling water too warm • Check the thermostatic control valve
Cooler clogged • Check and clean the cooling system
Lube oil temperature up • Fusible plugs have melted • Determine and correct cause. Install new
stream of lube oil cooler fusible plugs.
too high
Bearing temperatures Bearing damage • Check for smooth operation.

too high • Check the bearings and replace, if neces
sary.
Lube oil temperature too high • Check the lube oil heat exchanger
• Lube oil pressure too low • Check the lube oil system
Switch lube oil filters and clean filter hous
ing. Check pressure differential monitoring.
• Check the oil level.
Check the pressure relief valve.
• Increase the lube oil pressure.
Working oil temperature • Startup torque too high (high motor inrush • Check that driven machine turns freely.
rises to over 110 DC up current), driven machine blocked (see Check fusible plugs
stream of the working oil working oil temperature)
heat exchanger during -------------------------------------------------------------------
startup • Working oil pump does not deliver oil • Take the following actions:
Oil temperature in reservoir < 40 DC, re Warm oil in the reservoir to > 40 DC. To
sulting in poor air separation character do so, lower the cooling water flow rate
istics by partially closing the cooling water in
sible plugs.
tics; wrong 011 grade) necessary
Working oil pump pressure < 1.5 bar Check the work oil pump pressure at
pressure measuring points
Oil system not filled prior to startup Fill the oil system with the aid of the
auxiliary lube oil pump. Check the pip
ing system (correct routing of piping,
not draining into the oil reservoir)
Working oil heat exchanger:
• Cooling water flow rate too low • Increase the cooling water flow rate
Cooler clogged • Check and clean the cooling system
114
YOITM
Working oil temperature Working oil pump does not deliver oil Take the following actions:
rises to over 110°C up
stream of the working oil Oil temperature in reservoir < 40°C, re Warm oil in the reservoir to > 40°C. To
heat exchanger during sulting in poor air separation character do so, lower the cooling water flow rate
operation istics by partially closing the cooling water in
sible plugs.
pressu re test ports
Fusible plugs have melted Determine and correct cause. Install new
fusible plugs.
Working oil cooler:

Cooling water flow rate too low Increase the cooling water flow rate
Cooling water too warm Check the thermostatic control valve
Cooler clogged Check and clean the cooling system
Operating outside the performance charac • Comply with the design data, especially re
teristics specified for the project garding the characteristic curve for the
driven machine
115
VOITM
9.5 Smooth operation
Rough operation, vibra- • Poor alignment • Check alignment and correct, if necessary
tions and noise ----------------------------------
• Poor support between equipment and foun • Check the alignment and support; correct,
dation (foundation rails); uneven support; if necessary
equipment cocked
• Foundation bolts loose, defective founda • Check foundation; retighten the foundation
tion, foundation rails not grouted bolts, if necessary
• Wear or lack of lubrication in the connect • Check the connecting couplings, lube oil
ing couplings; sleeve in curved tooth cou supply and injection nozzles
pling does not move axially (teeth worn)
• Rotating components unbalanced • Measure the vibration and perform a fre

quency analysis on the entire system.
• Bearing damage Record the readings and operating data.
• Bearing damage • Check the bearings and replace, if neces

sary.
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9.6 Cross references
Topics Relevant documentation
Working oil cooler: Operating instructions for oil cooler in Chapter 14 ,,Attaching parts" of this documen
tation
Venting the working oil cooler Section 5.11.2 "Horizontal heat exc",angers"
Section 5.11.5 "Installing the vent lines"
Working oil flow rate Section 6.6 "Adjusting the working oil flow rate"
Alignment Section 5.9 "Machine alignment"
Operating data (pressures, tempera Section i ,2 "Operating data"
tures, oil flow rates) Section 7,3.1 .,Monitoring the equipment"
Orifice plugs for lubrication of exter Section of orifices for lube oil supplied to external units" on page 66
nal equipment
Foundations Section 5.10 ,.Securing the machine to the foundation"
Auxiliary lube oil pump motor Operating instructions for lube oil pump motor in 14 ,.Attaching parts" of this
documentation
Oil Section 8.5 "Test criteria and notes for evaluating working oils"
Oil level Section 6.2 "Fill the working oil"
Fusible plugs Section 8.6 "Replacing the fusible plugs"
Lube oil and lube oil pressure Section 6.5 "Adjusting the lube oil and control oil pressures"
Lube oil filter Section 8.4 "Cleaning the duplex oil filter'
Lube oil cooler Operating instructions for heat exchanger in

14 .,Attaching parts" of this
documentation
Scoop tube actuator Section 14.6 .,Voith electro-hydraulic position control unit"
Connecting couplings Operating instructions for connection couplings
in
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VOITH 10 Introduction to general
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 M overhaul
10 Introduction to general overhaul
Constant operation subjects units to natural wear, which is also influenced by

the surroundings. The scheduled reconditioning of your equipment minimizes
the risk of expensive production downtime. Our service department will develop
a maintenance strategy that precisely suits your needs. Professional and
regular reconditioning by our service team extends the service life of your Voith
product.
Contact our Service Center for further details: See contact information.
addition to the various speci'fic instructions.
Danger of crushing or shearing upper and lower limbs
During maintenance and assembly work, especially when turning shafts manually,
during assembly work and when positioning the machine, a person's fingers could
be crushed or cut off.
Risk of injury
Improper lifting of the Geared variable speed coupling can result in equipment
damage and personal injury.
The Geared variable speed coupling is to be suspended only from the specified lifting
points and in compliance with the ~ 15° angle of inclination as well as the minimum
crane hook height H.
Use only appropriate lifting appliances that conforms to safety requirements!
Damage to equipment and personal Injury
Improper disassembly and assembly of the Geared variable speed coupling can lead
to damaging the equipment and to personal injury. IA. CAUTION'
Disassembly and assembly work on the Geared variable speed coupling is only to be
performed by qualified personnel.
Observe the personnel selection and qualifications indicated in the Instruction

Manual!
118
VOITN 10 Introduction to general
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M overhaul
Used oil that escapes into the soil or sewage system can cause serious damage
to the environment.
Dispose of used oil in accordance with the national legal regulations!
Check for oil and leaks regularly!
Danger of slipping on leaked 011
Leaking oil on or next to the machine could cause someone to slip or fall and be
seriously injured.
Check for oil and leaks regularly!
Clean the machine regularlyl
Danger In areas that cannot be fully viewed
A person could be severely injured while working on the machine when starting it up.
Attach suitable protective covers that cannot be removed without the respective tool,
between the coupling and the shaft!
Only work on the machine when the system is shut down (no power)!
Operation is only permitted after visually ensuring that no persons are in the hazard
areas I
Risk of Injury
A person could burn themselves on the hot machine or on hot operational equipment.
Only touch the machine when it has cooled down!
Danger caused by Incorrect assembly
Not observing the correct direction of rotation could damage the machine and severly
injure persons.
The incorrect assembly of the machine or individual parts could damage the machine.
Note
iii
The Geared variable speed coupling and removeable parts of the Geared variable
J:
!·iii speed coupling are always to be put down on a suitable surface (e.g. rubber mat).
NOTE
Note
Keep access to the maintenance work areas free.

Pay attention to dimensions and design in the Assembly Plan!
NOTE
119
Voith Turbo I Geared variable speed coupling I SEC 56 Indonesia Pelabuhan I R 15 K 400 M overhaul
10.2 Tools and auxiliary means
• Standard tool kit Tools
• Torque wrench (See diagrams for torques)
• Measuring equipment
• Metric tools
• Lifting appliances
• Hydraulic pre-tensioning tool (HYDROCAM)
• Anchor eyelet for shaft end (Hirth-coupling serrations)
If necessary, these tools can be purchased from Voith. Disassembling/assembling the

Geared variable speed coupling requires no further special tools.
• Surface of rubber or similar material Accessories

• Fastening/securing equipment
• Sealant
Fastenlng-/securlng agents
Use fastening-/securing agents that comply with the drawing specifications for "Liquid
plastic".
Parts that are connected with one another must be
• clean
• oil- and grease-free.
Cleaning agent: trichloroethane or similar grease dissolving liquids.
Sealant
Sealant must meet the following criteria for use with the Geared variable speed
coupling:
• oil-resistant to 130°C
• does not contain silicone
Voith Turbo recommends HYLOMAR - L1 as sealant. The sealant is only to be applied

in a thin layer and ventilated for approximately 10 minutes. Observe other instructions
from the manufacturer.
Cleaning agent: trichloroethane or similar grease dissolving liquids.
1. HVLOMAR-L; Observe information on the tube when applying. Manufacturer - MARSTON-OOM
SEL 0-53909 Zulpich
120
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 M overhaul
10.3 Preparations
Before disassembling components of the Geared variable speed coupling,

do the following preparatory work:
1. Shut down driving machine, Geared variable speed coupling and allow to cool.
2. Electrically disconnect system motor.
3. Obtain approval to proceed with disassembly from the responsible party.
4. Disconnect electrical connections, when necessary.
5. Remove attached equipment such as cable ducts, wiring or sound insulation

covering based on the circumstances.
6. Make the lifting appliance (crane) ready for the Geared variable speed coupling
and components removed. Necessary weight speCifications are in the Instruction
Manual (BA1) SEC 86 Indonesia Pelabuhan.
NOTE
Comply with any additional special on-site safety information!
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VOITH 10 Introduction to general
Voith Turbo I Geared variable speed coupling I SEC 56 Indonesia Pelabuhan I R 15 K 400 M overhaul
10.4 List of components
Illustration 10-34: The design of the Geared variable speed coupling
1 Input shaft with gear 4 Auxiliary lube oil pump 7 Duplex oil filter
2 Coupling runner with primary 5 Scoop tube control with 8 Lube oil cooler
shaft (pinion gear shaft) scoop tube
and secondary shaft
6 Working oil cooler
3 Pump insert
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VOITM 11 Drawings, schematics,
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M diagrams
11 Drawings, schematics, diagrams
Horizontal section 20500542510
Vertical section 20500542510
Scoop tube control - CW 42591420
Pump insert 42012090
Pressure relief valve - Lube oil 42453070
Pressure relief valve - Working oil 42453060
Oil circuit and measuring point scheme 91600119810
Instrument list 91600119910
Logic Diagram 91600120010
Terminal Diagram 91600121510
Assembly Plan
- Geared variable speed coupling 91500119910 Sheet 1
- Geared variable speed coupling 91500119910 Sheet 2
- Heat exchanger Chapter 14.10 "Heat
123
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37. I
'Joith Lieferu'g
VO I TH SUJF:... Y
kelne Voith Liefecurg
NOT VO 1Tf! SUPPL Y 34 .23 TE\

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'i 34.6 Ii L (, p~-: NT
0, .'
J H'Hpt_tei Ie ur!d
',lAiN COMPGHEhTS
siehe :~\e"i\i(
'!IENTS S::E LI
1!9 l :1:
9I r OOll.'
,,«1--{j
Main Components and Instrument List
s
is
·OJ
Q)
a:
Item No.
Components or Instrument,
Type:
Manufacturer:
Measuring range
--
Adjusted range
Process Con nec-
tion
-
Electrical
Ingress
Protection
Measurement I I
Measuring point, 10- I Set value
cation 1
I
i Nominal
value during
operation
Remarks
Voith Customer TAG No Connection
B1 Radial bearing I
B2 Radial bearing
I
, I
B3
I Thrust bearing
I I
B4 I Thrust bearing I
B5 Radial bearing
I
B6 Radial bearing
I
B7 Radial bearing
I
B8 Thrust bearing 1I -+I

I
69 Thrust bearing II

610 Radial bearing I ,I
1 Mech, driven working oil pump II

I
-[
2. Mech, drive lube oil pump I
I
I
3 Internal aux. lube oil pump

Manufacturer: Rickmeier
I
I
I
I
4 Three-phase motor Power supply 380V 3Ph 150Hz
I
Manufacturer: ABB
I
Consumption: 11 kW
VOITH Scheme No. Order No. Code Date Type Revision Document No.
91600119810 38001567 SEC 86 Indonesia Pelabuhan 2008-03-17

R15K400M
9160011991 n I
Voith Turbo GmbH & Co, KG

D - Crallsheim
airek-MMar
Page 1 18
Item No. Process Connec

c Ingress Measurement! ;Jominal
0 Components or Instrument, Measuring range tion
'm
.;; Type: Protection Measuring point; 10- Set value value during Remarks
Ql
a:
Voith I
Customer TAG No
Manufacturer: Adjusted range Electrical
Connection
cation operation ~
II 5.1 I -+
I
I
~--JI
M
I
Check valve !\ux. lube oil purr:p
Manufacturer: Gestra
I
5.2 Check valve with orifice bore for
-t-
I Lube oil pump I
pump venting
I
I ~--
~ ~~
! Working oil pump I ----'
,'i
5.3 Check valve
6.1 Orifice plate AC.X. lube oii unrp. l i ,-

~
~'--~l-~ ~
I fJ I
I I j
Ii Input
EXlernallube oli, '
~ ----~I
-r r7~r- - -1~ ~ ~- - - +- - - ~- - -!~= = =~i~ ~ ~ ~ ~al~I~U~_~I'

6.3 Orifice plate !
, !
6.4 Orifice plate
I: working I , r - - I- - - - - - -
--I
6.5 Orifice plate Lube oilloil I
I ~-
I I II I
6.6 Orifice plate
i
M~,d~n
I Working 011 II :I I _,l
I
------+--______', I I
pump I
I ,0
I ! --l
~::==:~~~-L=~L=j==j~==fI== !~- -
_o __
6.7 Orifice plate Working oil
f-;;
6.8
7
Orifice plate adjustable
Pressure relief valve

Lube oil
I lJix" oil
· !- - --'j
: I
. I T
I I I Document No,
VOIT:H Scheme No.
91600119810
Order No.
38001567
Code
SECS61ndonesiaPelabuhan
Date
2008-03-17
Type
IR15K400;--111-----------1 160011
Revision
1
o - Crailsheim airek-MMar I I
~ ____________________ ____________..____________
~ ____________________L._____________
~ d~'~um~ __'~nNRU~_~m __ ~_Md_~.i~~
I __ ~~EW~~~~.
I Page 2/8 ~~
,
c
0
Item No.
Components or Instrument, I Measur~~H range
II
Process Connec
t~~_n
Ingress Measurement I
Nominal
I,
I
'UJ value during Remarks
Type: Protection Measuring point, 10 Set value

> i
(j)
I Manufaclurer: Adjusted range Electrical cation operation
0:
Voith Customer TAG No I
I
i Connection
8 Reversible double filter ON 65 Lube oil

Inserts: cleanable
Type. DU 63~ PN 16
25 f1m stainless steel mesh
Manufacturer Internormen EN 1092-1
I
I-_._----,".
n
J I Pressure relief valve I Working oil !
I
I
10 Control valve Working oil I
13 Pressure volume above scoop I
,I
tube piston I
I
14 Scoop tube piston I I
15 Pressure volume below scoop
I tube piston
I
t- -
16 I Scoop tube
I I
17 Fusible plug I
18 Voith variable speed turbo

I
coupling II
, I
I I
30.1 I Vent filter G1/i
I
I Type: I
I Manufacturer: Eppensteiner
! -~~-~-
i
t
34.1 Resistance thermometer -50 ... 180'-'C G/i IP 65 Temperature of ; P·Jarrrl
Type 2x PT 100 three-wire --- bearing 1
! I DO C 1< 90°C
I drawing no. )35240 M20x1,5
i rrip. I
I Manufacturer: Voith I Juchheim

I ~I
('C:
I
~J (
v
'
I

VOITH Scheme No. Order No. Code Date Type Revision

0- Crailshelm
91600119810 38001567 SEC S6 Indonesia Pelabuhan 2008-03-17
airek-MMar
R15K400M ---l91600119910 n
jPage 3/8
--.J
Item No. Process Con nee·

c Measurement i Nominal
a
.;;;
Components or Instrument, Measuring range tion Ingress
.s: Type: - - Protection Measuring point , lo- Se! value value during Remarks
Manufacturer: Adjusted range Electrical cation operation
'"
a:
34.2 Resistance thermometer -50 ... 180°C GY> !P (35 < ~JO C
Type: 2x PT 100 three-wire -- bearing 2 19O'C
drawing no.: 42(Ylr,240 M20x1,5 Trip
Manufacturer: Voith I Juchheim '" 95
!
34.3 Resistance thermometer -50 ... 180°C GY> IP 65 Temperature of Alarrn: [.-.... an "'-'
v\~
Type: 2x PT 100 three-wire --- bearirl£] 3 "' 90"C
drawing no.: 4.20;',5240 M20x1,5 Trip
Manufacturer: Voith I Juchheim 95C
34.4 Resistance thermometer -50 ... 180°C GY> lP 65 Temperature of Alarm: < DO
Type: 2x PT 100 three-wire --- bearing 4 t 90'-'C
drawing no.: M20x1,5 TI
Manufacturer: Voith I Juchheim
34.5 Resistance thermometer -50 ... 180°C GY> fP 65 Ternperature of A~arrlr GOC
Type: 2x PT 100 three-wire --- bearing 5 90"C
drawing no.: 42()35240

M20x1,5 I Trip
D5 C
34.6 Resistance thermometer -50 ... 180°C GY> IF' 65 Temperature of Aiarm < DO
Type: 2x PT 100 three-wire --- beanng 6 i 9D"C
drawing no.: 42035240

M20x1,5 I
I
Tr'.:)
,
C
i :
34.7 Resistance thermometer -50 ... 180"C GY> If> 65 Temperature of /\Iann < 9O'C
Type: 2x PT 100 three-wire --- bearing 7 A 9O'-le
drawing no.: 42G3S;MO M20x1,5 Trip
i
34.8 Resistance thermometer -50 ... 180°C GY> IP 65 Temperature of I AI !
Type: 2x PT 100 three-wire --- bearing 8 -~ SO"C
drawing no.: 42ll3524ll M20x1,5 lira
~
!
VOITH Scheme No. Order No. Code Date Type l\jo
91600119810 38001567 SEC S6 Indonesia Pelabuhan 2008-03-17 R15K400M

9"1 1 1
Voith Turbo GmbH & Co. KG airek-MMar
0- Crailsheim
Pnge 4! 8
I
Item No. Process Coonee

c Ingress Measurement I Nominal
Components or Instrument, Measuring range tion
.~
:> Type: -- - Protection Measuring point, io- Set va!u" value during Remarks
GJ Manufacturer: Adjusted range Electrical cation I operation
::r:
I
'~,-'
34.9 Resistance thermometer -50 .. 180"C G% IP 65 Temperature of !\l2nn < 90°C
1 ype: 2x PT 100 three-wire --- bearing 9 -~ 90"C
drawing no.: 035240 I M20x1,5 Trip
~"lanufacturer: Voith I Juchheim i A
G% I < 90 "C
I
34.10 Resistance thermometer
Type: 2x PT 100 three-wire
I -50 ... 180 a C
---
IP 65 Temperature of
bearing 10
Alarm:
190"C
drawing no.: I M20x1,5 Trip:
t 95 DC
Manufacturer: Voith I Juchhelm
I I
34.22 Resistance thermometer -50 ... 180°C G% IP 65 Lube oil tempera- Alarm: < 65 DC with thermo well
IType: 2x PT 100 three-wire --- I lure upstream of t 65°C
drav;lIlg flO.· M20x1,5 cooler Trip
i Manufacturer: Voith I Juchheim 'I' 70 (;C
34.23 ReSistance thermometer -50 ... 180C G% IP 65 Lube oil tempera· ;\ianr < 55°C With thermo wei!
Type 2x PT 100 three-wire --- ture downstream of 155 C
draWing no.: M20x1,5 cooler
Manufacturer Voith I Juchheim C
34.25 Resistance thermometer -50 ... 180"C G% IP 65 IWorking oil tem- Alarm: < 110 "C Iwith thermo well
Type: 2x PT 100 three-wire --- perature upstream t 110 "C ,
I, drawing no.:
Manufacturer: Voith ! Juchheim
M20x1,5 of cooler Trip:
t 130°C
I
I
I
34.28 Resistance thermometer -50 ... 180°C G% IP 65 Working oil tem- Alarm: I >35<75°C Iwith thermo well
Type: 2x PT 100 ttlree-wire --- perature down- 175 "C
drawing no,' M20x1,5 stream of cooler Trip·

I
Manufacturer Voith I Juchheim l' 85
~
--
36.0 Pressure gauge o . 6 bar GY> IP 65 Working oil 1.8 ± 0.5
IT ypeW
Manufacturer Dresser Ashcroft
I
I
pressure bar
- I
VOITM Scheme No. Order No. Code Date Type Revision Document No.

91600119910 n
0- Crailsheim
airek-MMar .
I Page 5/8
.~~--
c
0
Item No.
Components or Instrument, Measuring range
Process Connec
tion
I Ingress I' Measurement! I Nominal
"(i)
'> Type: - Protection Measuring point , 10" i Set value value during Reularks
(b
a: Manufacturer: Adjusted range Electrical cation ! operation
I
I I
36.1 i Pressure gauge 0 bar !I GYz IP 65 Lube oil 2,5 - 3.5
Type VV I pressure II bar
Manufacturer' Dresser Ashcroft I
---i- -
36,2 Pressure switch 0,3 - 5,2 bar Y. NPT IP 65 Lube oil Main motor release: 2,5 - 3.5 Power rating:
Type: 44Vl -- pressure l' 1,7 bar bar 110 A 250 VAC
Manufacturer: SOR :y" NPT, i with two independently adjustable
Trip: I setpoint values
J, 0,8 bar
I I
j
! 36,3 Pressure switch 0,3 - 5,2 bar Y. NPT IP 65 - t u b e oil Aux, lube oil pump 2,5 - 3,5 ! Power rating: •
I Type: 'J,N":,, -- pressure I OFF iJar ' 10,A 250 VAC
I Manufacturer SOR % NPT, I with timer with lwo Independently adjustable
, after !naili iTl0tor setpomt values
I run-up
! I! 2,2 tiar Timer is no! VDlth suppiy
I
IAlarm! ,,,",liX, lube
i oil pump
ON
I J 1,5 bar I I
I
37,1 Differential pressure indicator 0- 100 % G Y4 IP 65 Differential pres- Alarm / - clean fll < 0,8 bar Power rating:
with switch -- sure ter: 230 V AC; 0,5 A
I Type: 11 M12 Lube oil filter l' 0,8 bar 10W
175 V DC; 1,OA
I
Manufacturer: Internormen
I 20W
i
40.1 Oillevei Indicator 300 mm I G2Yz
, Oil level I Between
Voith dwg,
i min- and
I
Manufacturer: Weka I max. oil
level
I I ~
VOITH Voith Turbo GmbH & Co, KG

Scheme No.
91600119810
Order No.
38001567
Code

Date
2008-03-17
Type
R15K400M
Revision Document No.
9160011991
airek-MMar
D - Crallshelm
I 6/8
r Process Connec-
- ~-
t: Item No.
0 Components or Instrument. Measuring range tion Ingress Measurement I Nominal
'w Type: - -- Protection Measuring point. 10- Set value value during Remarks
s
Q)
a: Voith Customer TAG No Connection
I 44.0 Voith electro-hydraulic positioning I IP 65 , Input signal

control (Vl:.HS) ! 4 - 20 mA
Output signal
-+-_-t•
4 - 20 mA.
:
II I Power supply
I I 124 VDC,
I I M"lm"", w"'p' ,oo,p",,,"""

(temporarily):2.5 A
I
I I -
! 44.1 4/3-way valve with solenoid con- I, I I
I
tral system I I
44.2 Electric position pick-up I

I
50.1 Lube oil cooler I I Supplied by customer

I ---1--
50.2 Working oil cooler
I I ISupplied by customer
! I I
52.1 Working oil cooler venting orifice Supplied by customer
-*5
I
60.1 Test connection 1'v11 Working oil
i I I pump pressure bar
60.3 Test connection M3

I Working oil
pressure
I
<3 bar
I
60.4 Test connection M4 ontrol oil pressure I " 5 0.5 bar
1°
I
70.0 Shutoff valve With vent valve Process:
Type: Y:> NPT Test
Manufacturer Schneider Y. NPT
I
I
I Instrument: G"h I
I
I
I I j Document No.
VOITH Scheme No. Order No_ Code Date Type I
Revision
VOlth Turbo GmbH & Co. KG

D - Crallsheim
91600119810 38001567 SEC S6 Indonesia Pelabuhan 2008-03-17
airek-MMar
1 R15K400M J___. I 19160011

IPage 7 18 --."-~--
1 en
i
Item No. Process Connec

c Ingress Measurement I ~.ominal
0 Components or Instrument, Measuring range tion
'iil
'>ill Type: -- - Protection Measuring point , 10- Set value value during Remarks
IT:
70.1 Shutoff valve Y, NPT
Type: I
Manufacturer: Schneider I
I
I
,
I
70,2 Shutoff valve
drawing no.: I I GX
I
I
Manufacturer: Internormen
I I
75.1 Oil drain flange below DN 32
PN 16
I EN 1092-1
75.2 Lateral oil drain G1X
(G 1 X thread)
I
75.3 Oil suction pipe DN 50 I
(VTC flange surface) PN16 II
EN 1092-1 I
VOITH Scheme No. Order No. Code Date Type Revision Document No.

91600119910 en
airek-MMar
D - Crailsheim
I Page 8! 8
--
VOITH TURBO
POWER TRANSMISSION
Variable Speed Drives
Voithstrasse 1
D-74564 Crailsheim
Tel. 07951 /32 - 0
Fax· 07951 /32 - 650
C
I Code SEC S6 Indonesia Pelabuhan
VC product R 15 K 400 M
I
,t
Order number 38001567
Drawing number 91600120010en
Designation Geared Variable Speed Coupling - Logic Flow Chart
Symbolic files
I File J :\Turbo\ai-VTCR\air\BA-Doku\916\000501-00 1000\9160012001 Oen. pfd

i
_. I,
I Issued on 08-03-17 by rJ1Mayer Number of pages 26
J
Date 08-03-17 SEC S6 Indonesia Pelabuhan VOITH TURBO Cover sheet Order No. 38001567
Editor M.Mayer
Date R 15 K 400 M Dept.airek Drawing No. 91600120010en Page 1
Index Rev. No. Date Name Checked 26 P
r _. . . ".... ~ ~ ~L. L. . ...- ___ , ,~,..,

Contents
Ipage no, ipage description ,
1 Cover sheet i
--~-~~
---_. -~-
2 Contents
3 Revision list
;g
4 General comments
5 Pre-start conditions part 1
- ~---
-
6 Pre-start conditions pali 2
7 ,Pre-start conditions part 3
~---.---- --~---'-~--
8 iMain motor start circuit part 1
9 !Main motor start circuit part 2
10- - 'Lube oil pressure checks part 1
11 I Lube oil pressure checks part 2 I
12 ,Filter check
13
-~-,-
Bearing temperature checks part 1

~~--
I
~-~- .--
14 Bearing temperature checks part 2
~~--- -~
- _.
-------~--
---------
18 Bearing temperature cr,ecks part 6
19 Oil temperature checks part 1
20 !Oil temperature checks part 2
21 Main motor stop circuit part 1
22 Main motor stop circuit part 2
23 Description of symbols part 1
------ -~

.: --~

_. ---- -~
~-----
-----
---- ------------ --
-----
Date 08-03-17 SEC S6 Indonesia Pelabuhan VOITH TURBO Contents Order No, 38001567
Editor M.Mayer
I
Date R 15 K 400 M DepLairek Drawing No,: 91600120010en Page 2
Index Rev. No Date Name Checked 26 p,

",:]rlv.. ",re-Copyright by Triple-S GmbH.
I
'------------,
Revision list
I
•Revision description ReViSion !\lo.
ipage
Date 08-03-17 SEC S6 Indonesia Pelabuhan IVOITH TURBO Revision list Order No.: 38001567
Editor M.Mayer
I t=-.
I i
Date R 15 K400 M IDept.airek Drawing No.: 91600120010en lrage3

Index Rev. No.
--
Date Name Checked 1"6 P.
('
i
- I ---'-J(l;lVvale~Copyright by
""""' ....
lrtf)le-,:"} GmbH,
This is the input side. This is the output side.
GENERAL COMMENTS
Identification of symbols for logic flow chart. please refer to the last 4 pages of this document.
For item numbers and sWitch pOints, please see Oil Circuit and Measuring Point Scheme 91600119810
Before test run and after each overhaul, all switch points and connections have to be checked or adjusted.
For switch points, see Instrument List9160011991 O.
I
I I
I I
I I
I I
I I II
I !
I
I I
I I
I I
I I
I I
Date 08-03-17 SEC S6 Indonesia Pelabuhan VOITH TURBO General comments Order No .. 38001567
Editor M.Mayer
Index Rev. No. Date Name Checked 26 p
- . - -" -
Bearing 1 temperature
> 90 'C ~
item 34.1
Bearing 2 temperature -+ ( 013~

> 90 "C
item 34.2
-H14"
-~
> 90 'C
item 34.3
Bearing 4 temperature ~
> 90 "C
item 34.4
Bearing 5 temperature V 15'

> 90°C
Item 34.5
r-~U_j
Date 08-03-17 ISEC S6 Indonesia Pelabuhan VOITH TURBO IPre-start conditions pari 1 Order No.: 38001567
Editor 1M Mayer
Date R 15 K 400 M Dep\.airek Drawing No .. 91500120010en Page 5

Index IRev. No. Date Name Checked 26
Software-Copyright by Triple-S GmbH
> 90°C
item 34.6
i ~
I
l
I
Bearing 7 temperature I
t--@:fD
> 90 "C
item 34.7 I
I
( T16 )
Beanng 8 temperature
> 90°C I
item 34.8
i
!~
i
> 90 °C I
item 34.9 I
I
I
l"j"17
'. 7~ .,
~}
> 90 "C
item 34.10
I
I
i
I
I
I
I
I
I
I
I
I
I
I
I
I
i
I I
i
,
I ;:>1 I
I
I I
Date 08-03-17 ISEC S6 Indonesia Pelabuhan VOITH TURBO IPre-start conditions part 2 Order No.: 38001567
~--~------~----~-----+-----+I--~
Editor IM.Mayer
Date R 15 K 400 M Dept.airek Drawing No .. 91600120010en Page 6
Index Ir~ev. No. Date Name Checked 26 P

Software-Copyright by Triple-S GmbH !':e,jCw;uurg
Lobe ,iltemp. 0p"ffi,m
of heat exchanger
r . I
~
> 65°C
Item 34.22
Lube oil temp. downstream ,I c:J1Ji)
of heat exchanger
> 55°C
I,
item 34.23
Working
"1 01 temp. upstream
of heat exchanger
> 110°C
TI II I ~ X20
.
item 34.25
Working oil temp. downstream " I I I W20 "

~
of heat exchanger
> 75°C
item 34.28
I
::>1
~-----------------------~~
Date 08-03-17 ISEC S6 Indonesia Pelabuhan VOiTH TURBO IPre-start conditions part 3 Order No.: 38001567
Editor IM.Mayer
Date R 15 K 400 M Oeptairek IOrawing No. 91600120010en - ipage 7 I
Index IRev. No. Date Name Checked 26 ~
I
Sofiware-Copyright by Triple-S GmbH. RcqensbufU
I
( G5
( N6 ,
( ASr
I
I
I I
21
I
I
I Y
T
All variables within limits
I
I
Start per
missive
I
I
Cooling syste I
heatexchang
in operation
(operator act
1 1
Unit ON (operator JJ &
1
i CS I Aux. lube oil pump ON I Ii
Lube oil
pump i T
l ~O)
\_-~~::'..::--j
Date 08-03-17 ISEC S6 Indonesia Pelabuhan VOITH TURBO IMaln molor start circuil Order No .. 38001567
Editor M.Mayer part 1
Date R 15 K 400 M Deptairek Drawing No. 91600120010en Pag~
Index IRev. No. Date Name Checked 26 P. I
:;oftware-Copynght by Triple~S GmbH
~~--------------------------------~
Lube oil pressure
> 1.7 bar
item 36.2
&
!
1-----',-- -i Scoop tube min position
Scooptub~ L I_ _ _ _ _ _ _ _ _ _, _ _ _ _ _ _ __ _
----r---i
S iv1a.n motor ON 'I R
Main
motor
f'!'
iL - .<~,
l T = ..... ~
! I
~-----'----, '----r-'I
1
.-'---~i ~ I~
I
I
{~ ~
~
~----.J
i
._____0',_._-
Scoop tube position> [nlil
Re!ease r-
I '--1- - - - - - - - - - - - '
LLI
, I
I & I
Y I
e r m a l operation
I
l
~_+---____I--_ _+-__-+I_Da_t_e_--+tO_8_-0_3_-1_7-lIS EC S6 Indonesia Pelabuhan VOITH TURBOIMain moior stan CIrCUit No_ 38001567
Date R 15 K400 M Deptalrek ~~o. 91600120010en s

Index IRev. No. Date Name Checked
Lube oil pressure
> 2.2 bar
Fl
I '~. -'~,---~l
item 36.3
I
I~~ I
II r-.
I
------r--'---~:,
i
0 ,c ,c
I I I -I
,-,r I Aux, lub~ "II
( F9 L-r I I~ u0
ll~rrn:_n- - - - '
'I '
III (AD111
-------""
Lube oil pressure
<1.5bar
item 36.3
[I& I I
I
~
_-.l
i l I
I ~-.---., S Aux lube oil purnp ON
IL I
j ----l
~
!\!arm:
Lube oii pressure low
1-_+-____I--__+-__-tI=-Da___t-e---+tO___8___-0:-3--1-7-1IS EC S6 Indonesia Pelabuhan VOITH TURBO ILube oil pressure checks pari I No, 38001567
Editor M.Mayer
Date IR 15 K 400 M
Dep!.airek 91600120010en
Index IRev. No. Date Name Checked
I I
( AD10
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
Lube oil pressure I
< 0.8 bar
item 36.2 I i
I I
I I I
I
I
I &
I i
y
I I Trip
I ,.....,--- Lube oil pressure low low
JI S I
I
. Trip
Lube oil pressure low low
I
I
I
I
I
\. R21 ) I
I
Date 08-03-17 SEC S6 Indonesia Pelabuhan VOITH TURBO Lube oil pressure checks part 2 Order No.: 38001567
Editor M.Mayer
Index Rev. No. Date Name Checked 26 P.
;:;.oftware-Copynght by 1nple-S GmbH, Regensburg
I I
Differential pressure
I
I
I
I
I
I,
,
at lube oil double filter ~ I
> 0.8 bar
item 37.1 I I
I I
I I
,I
II I
I
I
I
I I
I I
I
I I
I IDifferentialAlarm:
pressure at lube I
I I oil double filter high I I
Alarm·
1 I I I Differential at
I I lube oil filter high
I II
I
,I
I I
i
II
I
I I
I
I I Change over manually to
I
second filter,
I clean the filter element I
I I I
I I
I I
I I
I
I I
I I
I I
Date 08-03-17 SEC S6 Indonesia Pelabuhan VOITH TURBOIFilter check Order No.: 38001567
Editor M.Mayer
--
Date R 15 K 400 M Dept. airek I DraWing No .. 91600120010en Page 12
_. -----
;:,oftware-Copyright by r rlple-S GmbH_ R_elJensburg
I I
I I
( AB5 I I
I I I
Alarm
I I
Bearing 1 temp. high
I
I
I I I
I
I A18 )
I I
Bearing 1 temperature I I
~
> 95°C I
item 34.1
I
I I I Trip I I
S I Bearing 1 temp.
I high high I
I I
!
I I B18 )
I I
I I
( 05 I I
I i I
I Alarm I
Searing 2 temp. high I
I I I
I i K18 )
I I
I I
> 95°C I I
I
item 34.2
I I
I S I . ,Trip. . i
Sealing 2 temp. high high I
I I I I
I
I
I
I I I
I OJD
Date 08-03-17 SEC S6 Indonesia Pelabuhan VOITH TURBO Bearing temperature checks Order No .. 38001567
Editor fV1.Mayer part 1
Date R 15 K 400 M Dept.airek DraWing No. 91600120010en Page 13
:
Index Rev. No. Date Name Checked 26 P. i
0oftwar"e-Copyrighl by rnpJe-S GmbH, RegensbwQ
~~+---------------
Alarm:
--------------o-~
> 95 °C
item 34.3
Trip:
Bearing 3 temp. high high
I
.-lC::S2D
I
~~----------
~
I
Alarm . h
Bearing 4 temp. hlg
I,
Bearing 4 temperature - - r - - - - - - - - - - - - - - - - - - - - - - - - - ,
Y
i : Q1D
> 95"C
item 34.4 I
r~-··------·I Trip
I; I is l.§.earing 4 temp. high high,
AE18)
Date SEC S6 Indonesia Pelabuhan VOITH TURBOIBearing temperature checks Order No. 3800156l
~-+-----+---+_---rl----4_ __~ part 2
Editor
Date R 15 K 400 M Deptairek Drawing No.. 91600120010en Page 14

Index IRev. No. Date Name Checked 26 p
. " ' - - - - - - . - - - - -....
S-of·-,-.p-.fe-... b~·l7,,!e-s!GmbH f', '~;;b;;';
C·o·Py·'·ig.,.,,-'
~I
I
:--t
~T~
r-l: S
Alarm
Gearing 5 temp. high
l ------ -~:-(AF 18)
5temp;~~~~
i
Be,ri09
item 34.
5
iQ' -- I
.----L!
"Tri"
II
s
I
1
Bearing 5 temp. high Illgh ,
. ,.
.AG18 i
. , 1 (A08)
I
I
~-+----------------------------------~
~----, ~ ~ t m"
~!::'
, Alarm
i H
! I
- 1
S I Bearing b
,
___"
~L-______
Ii .J ! I
~8"l
( A1--I
1
Bearing 6 temperat~re -~--------------------- ---1

~~ ________ :;.i-:- ____ 'I
> 95 C , r---r "'P . ,

Item 34.6 i S I 8.""9 G temp h'9 1,,"9"J
I '~
L____ ______
I I
-I ______________._. __ ;____ ( 1\.118")
Date
I ISEC S6 Indonesia Pelabuhan
108-03-17
~--+---------r-----~----~=Ed~i~to-r--tM~.M~a-y-er~
VOITH TURBOIBearing temperature chocks N 3800 567
part 3
Date IR 15 K 400 M Dept. airek

I No.. 916001200100n 15
Index IRev. No_ Date Name Checked p
I bV Gnlt1H
~~----------------------------
Alarm:
I
~
I
Bearing 7 temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
> 95°C
item 34.7
( AK18 '\
~~----------------------------------~
~
~
--;;-- AI"m
Be,,'og 8 temp high
L -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~~
> 95°C
item 34.8
I
r-C
I
AM 18)
1-_+-____+ __--t___-+tD_a_te_ _}O-:-8-:--0:-3_-1_7-jISEC S6 Indonesia Pelabuhan VOITH TURBOIBearing temperature checks Order No.. 38001567
1--\------\---- I
Editor MMayer
I
part 4 I
Date R 15 K400 M Dept.airek Drawing No.: 91600120010en Page 16
Index IRev. No. Date Name Checked 26 P
Software-Copyright by Triple-S GmbH, Reucnsburg
~~--------------------------
A!a-r'-II-:---i
L -__ ~
_____- - - - ,________ I
I
~~
Bearing 9 temperature - - - . : . . . - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
> 95 °C
ilem 34.9
~)
~ I
i I I
I
I Alarm I I
S I Bearing 10 temp. high I
I L-Jj i
I
I I ~
I I
Bearing 10 temperature I I
I
> 95 °C
item 34.10 I I
I
i
I
~.
S . Trip
,
I 8""cg 10 "Imp h'9 1, high I
I
I
j
I I
(A018 )
I I
Date 08-03-17 SEC S6 Indonesia Pelabuhan VOITH TURBO Bearing temperature checks Order No. 38001567
Date R 15 K 400 M Dept.airek DraWing No. 91600120010en Page 17
Sof!ware-C0f.lyn9hl by Triple-S GmbH, Rcucns[mrg
- I
I I
I I
! I
A13 I :>1 I
K13 I
P14
Z14
I I
AF15 I
I
I 'l I
II
AH15 I
AJ16
AL16
I
I
> J I
AN17
AP17 I
I Alarm:
Bearing temperature high
If necessary, go to
I logic "Unit OFF"
I
\operator adon).
813
I :>1
L13
,
Y14
AE14 I I
AG15 I
'--- I
I I
I c' J
AI15 I
AK16 II
I :>1 Trip:
AM16
Bearing temperature high high
A017
AQ17
I
-+-
I
--
-
1 I
I @L)
I I
I I
I
I 1
Date 08-03-17 SEC S6 Indonesia Pelabuhan VOITH TURBO Bearing temperature checks Order No. 38001567
Date R 15 K 400 M Dept.airek Drawing No.: 91600120010en Page 18
Index Hev. No. Date Name Checked I 26 P
I
Software-Cor.;yright oy Tnp!e-S GmoH, kcqensburo
i Alarm
Lube oil temperatu~I _ _ _ _ _ _ _ _ _ _ _ _ _ __ L- ________+-__

Lube oil temperature high
upstream of cooler
If necessary. go to
> 70°C I logic "Unit OFF"
item 34.22
Trip:
(operator action).
upstream of cooler
high high
Trip:
Lube oil temperature high high
~)
C9D
L __
Alarm
Luoe oil temperature
downstream of cooler high

I I Alarm:
Lube oil temperature high
I If necessary. go to
> 60°C
I
J
logic "Unit OFF"
item 34.23 I I
S I Trip I (operator action).
I I Lube oii temperature

dC\ivnstream of cooler
l fl:gl", hIgh
I I
I
i
IL-
.
I
Trio
LUbe ali temperature high high

I I (AC2T)
Date 08-03-17 SEC S6 Indonesia Pelabuhan IVOITH TURBO

Oil temperature checks part 1 Order No. 38001567
--r
Editor M.Mayer
Date
15 K400M IDept.airek
Drawing t'Jo.· 91600120010en Page 19
p
Index Rev. No. Date Name Checked
i r' ___ , ._,_j.... ..,"_, •• ,_ ,-'.
26
,-,_. L" "'
I
Werking od temperature
i ups:ream of cooler high
Alarm
I
Working oil temperature high
i ________________2-___ If necessary, go to
Working oil temperature L-
logic "Unit OFF"
~
upstream of cooler action).
> 130 'Ie I
-----L-.. _ _ _-,
item 34.25
Trip:
I
upstream of cooler
high high
Trip:
I high high
I ~
I
W7
, S
I
I !\!arm
! Working oil temperature I
I downstream of cooler high I Alarm:
I II Working oil temperature high
> 85 DC
I I I
If necessary, go to
logic "Unit OFF"
item 34.28 I I I (operator action).
I
I i I
~
Trip: !
I Working oil temperature
I
I
I high hig I
I I I Tnp
I L I Workmg oil temperature
I
high high
I I
(AX21 )
Date 08-03-17 SEC S6 Indonesia Pelabuhan VOITH TURBO Oil temperature checks part 2 Order No.: 38001567
Editor M.Mayer
Date R 15 K 400 M Dept.airek DraWing No.: 91600120010en Page 20

Index Rev. No Date Name Checked 26 p,
:-:joftware-Copyright by Triple-S GmbH, RegenS!JI'f~J
I I
Normal UNIT STO~ I
I I ;>1 ?l I
( R11 J
I ,--- I
! - - - I
( Ci8
I - r--
I
I I
(
(
(
AA19
AC19
AW20
I
I
>!
I
I
I I
I
J I
( AX20 Aux. lube oil pump ON
I - Switch on I I !
I I I
I I
I Main motor in operation I
I I I
I
I
i
Main
motor
S I Main motor OFF 12R I I
,
I
I
I I I
I I
I I
I T 0
I I I
Timer for run-down \ = .... s' I Actuator min. position I R I
I I I i I !
Prepare
I I I
I
I I I
I
I & I
I I
I I I M22
Date
Editor
08-03-17
M.Mayer
I
VOITH TURBO Main motor stop circuit
part 1
Ordel' No. 38001567
I
Date R 15 K 400 M Dept.airek Drawing No.: 9i600120010en Page 21
Software-Copyright by 1 riple-S Gmbf'l, Re;JensbuiT!
I I
( M21
!
I
I
I
I
I
0 I
I
Aux. lube oil pump OFF
I
I
I
I
I
I
I I
I !
I I
I I
I I
I I
I !
I
I
-L Unit OFF
I
I 1
I
I I
I I
I I
I I
I I
I 1
I I
I I
I I
I I
I I
I I
I
Date 08-03-17 SEC S6 Indonesia Pelabuhan VOITH TURBO Main motor stop circuit Order No.: 38001567
Editor M.Mayer part 2 I
I
f-------
i
Index Rev. No. Date Name Checked 26 P I
Software~Copyright by TripJe-S GmbH, kcgcnsburg
I I
0- S
This is the input side. AND This is the output side.
The output will be in the i-state Bistable logic function symbol I
if all the connected inputs are with prevailing S input I
in their defined i-state.

I
II

-1S L
D-
NAND
-b
The output will be in the O-state Bistable logic function symbol
if all the connected inputs are with prevailing R input
! ,
in their defined i-state. I
~
I
0
OR
The output will be in the 1-state T=8s
ON - delay (8 sec) I
!
I
if any of the connected inputs is

in its defined i-state.
I
D
NOR
The output will be in the O-state
if any of the connected inputs is
in its defined i-state.
$ T=2s
OFF - delay (2 sec)
I
I
ON - delay (3 sec) I
I 3s/12s
ITI T2, I I
and
,I

I OFF - delay (12 sec)

NOT (Negator/lnverter)
I -i~
L-.J The output will be in the O-state
if the Input is in the defined i-state.
I
I
I I
I
I l~lJ
T = 20
.,
gc
The output pulse time is
always 20 sec independent
of the input signal duration
I The letter indicates the signal,
the number indicates the page
I
j where the signal is going to.
I I
I
024
I
,I
I Exampie of a connection !
to another page
Date 08-03-17 SEC S6 Indonesia Pelabuhan VOITH TURBO Description of symbols part 1 Order No.. 38001567
Editor M.Mayer
Date R 15 K 400 M Deptairek Drawing No. 91600120010en Page 23

Softlivare-Copynghl by TnpJe-S GmbH, Regensburg
This is the input side. This is the output side.
( Q23
Example of a connection
from another page
lU
&
Unused inputs do not
The letter indicates the signal, count in the logic flow chart.
the number indicates the page
where the signal is coming from. -'LJ~
111--,
I ~ I I I
Connections are marked with a dot.
Q- This is the initial step in a process

representing the start conditions.
c> This is a step In a process.
~
I
This is a step in a process.
The dot indicates that its condition
is logic 1 (fulfilled).
+ This IS a transition. It is located between
steps and descibes the necessary
actions between the steps.
J This is a step with a

description of the step.
Main motorl
1--+_ _ _+--_--+__-+-_----1if:-::08-:--0:-3-_17-1lsEC
Date S6 Indonesia Pelabuhan VOITH TURBO IDescription of symbols part 2 Order No. 38001567
Editor 1M. Mayer
Oate R 15 K 400 M Dept.airek Drawing No. 91600120010en Page 24

Index I Rev. No. Date Name Checked 26 P
Sottware-CuPywJht Dy Tllp!e-S GmbH, Regensburg
I "Oil
I
$-1
I I
.~
This is the input side. I I This is the output side.
I
I
"A'
I'~ I
I
I I
The symbol on the right-hand of the step-symbol is an action symbol.
I The action symbol can exist of 3 fields (field "A", "8" and "C").
I
I I
Field "A" or "e" are to be used only if required.
I I
I ,I
I Field "8" describes the action if step "X" is fulfilled.
I
I
I I
Field "A" descibes the correlation between the step "X" and the action "8".
I the follOWing letters are to be used: I
S stored
I D delayed
I
I
I L time limited I
P pulse shape
I C conditional I
I Letter combinations can be used, therefore the order the letters are written is important. I
I I
For example: "A" = DSL The input signal "X" will be delayed, stored
I and the action "B" limited to a certain time. I
I If letter c (conditional) is used the action is only enabled if the condition descriped under "D" is fulfilled.
I
I I
For example: "A" = SLC
I "8" = lube oil pump ON I
"0" = oil level ok
I I
I The input signal "X" will be stored and the lube oil pump will be switched ON for a limited ,I
time if the oil level is ok.
I I
I I
I I
Date 08-03-17 SEC S6 Indonesia Pelabuhan VOITH TURBO Description of symbols part 3 Order No. 38001567
Editor M.Mayer
Date R 15 K 400 M Dept. airek Drawing No. 91600120010en Page 25
0ottwLlre-Copyright by TripJe-S GmbH, ReqcnstJurg
I I
I I
I I
I I
I I
Field "C" describes the feedback of the command "8".
I The following symbols can be used I
I A Command output I
R Command effect is achieved (response control)
I X Fault signal, command effect is not achieved I
1,2... No. of feedback
I I
I For example' I
I
"A" = DSL The input signal "X" will be delayed, stored
II
I and the action "8" limited to a certain time.
I If letter c (conditional) is used the action is only enabled if the condition described under "8" is fulfilled. i
! I
For example: "A" = SLC
i "8" = lube 011 pump ON I
"D" = oil level ok
i I
! The Input signal "X" will be stored and the lube oil pump will be sWitched ON for a limited I
time If the oil level is ok.
I I
Field "C" indicates the feedback of the action to be carried out.
I In the above example "C" would indicate logic 1 if the lube oil pump IS ON. I
I I
I I
I I
I I
I I
I I
i I
I
I I
I I
Date 08-03-17 SEC S6 Indonesia Pelabuhan VOITH TURBO Description of symbols part 4 Order No.: 38001567
Editor M.Mayer
Index I"ev. No. Date Name Checked 26 p
~)0ftware-Copyright by lriple-S Grnbl-j, I\CHeflsburg
__"__ ~._.~ __,~_ _1 --------- -_._------ ---~-~----
VUl1203/?J. Feb. 200<+
VOITH
VOITH TURBO GmbH & [0. KG

Voithsteasse 1 74564 [rallsheim
Tel 07951 / 32-0
Fax 07951 / 32-650
Client Shanghai Electric (Group) Corp. Ltd.
Unit designation R 15 K 400 M
Order number 38 001 567
Drawing number 916 001 215 10 en
Code word SEC S6 INDONESIR PELRBUHRN
Regulating and [antral Voith Electro-Hydraulic Positioning System
Equipment Type VEHS / Balluff - BTL 5-El0-M0150-B-KR 05
File name without \EPLRN\P: \VOI\GR_200S\916 001 215 10 EN
CRD - Symbolic files DIN WUP/VC SYMBL
Designation ~JIRING DIRGRRM

Department airea-Ga
Created at 20.03.200S
Revised edition 20.03.2008 by Gaugler
........................................................IB. . . .IB................IB......IBBI............IBIB. . . .IBIBIBIB....IBIBIBIBIBIB~-~igmgmmllB~IBIB~I~Mru~ 5FItiigl~~
2
INDONESIR PELABUHRN v0 I T H T UR B 0 leo v e '" sheet I
f"-'-'''''-''''--~§. -0 0 L 5 6L____I:~:_:
I
" - -=~~~:I=_~I
I
400 M [Oep ail-eel-Ga
"-"-- -_.- ---------.---~-~-------.--.--~--.-~--,- I. 01h n 1') r.:: -1 . 1-'--'-'---.
Rp[Jli'\l.ir-'9 Rj~p18r"d by IU' Clumh", ::J1.U u01. Ll:J 1.0 en 13,'"
,
~ j 5 __~_"-_____ I--=-____=~=-~=~:=r-----~-8==-~=~~L __
Table of contents VOl 1201 / 72 Mar z 2nO]
Page no. Page descrlption Letter additional fleld Date Edltor
1 cover sheet 20. 03. 2008 Gaugler
table of contents 20. 03. 2008 Gaugler

Junction box Jl / view / layout 20. 03 2008 Gaugler
4 reslstance thermometer PT100 20. 03. 2008 G aug 1 e ,.
5 reslstance thermometer PT100 20. 03. 2008 Gaugler~
6 resistance thermometer PT100 20. 03. 2008 Gaugler~
7 reslstance thermometer PT100 20. 03. 2008 Gaug 1 e r'
8 resistance thermometer PT100 20. 03. 2008 Gaugler
9 spare terminals Termlnal slrlP -Xl 20.03.2008 Gaugler
10 p r- ess U [. e s wi l c h 20. 03. 2008 Gaugler
11 differential pressure sWltch 20. 03. 2008 G() U 9 1 e r"
12 power supply 230VRC/2UVOC 20. 03. 2008 GauSjlel'
13 I Voith Electro Hydraullc Positioning Control - VEHS - 20. 03. 2008 I Gaugle'
L=~===- ____________-=== 1
~.-------------
1I
t
!
,
1
1
--
- .- I
]
--------~
I ~- ~~-~-----!
I
3 I
1-I______j.______ j_~""---~~03 201181 SEC
_g_~l t or~aug.l er-
S 6 IN DON E SIn PEL R B U HR N r--v 0 I T H . T U RB 0 'I tab 1 e of contents
~'-2:'-n' 38 Q_Q L 567 , [~=------ H~_=21
I I
----. --n,,_l:"-~ 2;;-Q3~2u D81 R
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fj"tP. IN~)me IChp.cked I lUI iQlfl<'ll ;RpP.lnr:Tnq IRep'l<lU!U bv ill, a,,',,! numbp, 916 001 215 10 en ~~j
~ ___ ~~_ _ _ ~ _ _ _4 c 8 _~_L__ ~ '-- --- _I
junction box Jl
fr'ont VIew side view Supplier. Eldon
I
8 Ll 0 0 21 D. [) T y p e: RSR 08082
I
I I
unction box
dlmenslons: 800x8 Ox210 mm
de. of
pro ~ctlon: IP c;
~,
ITIClte.r-lal: stainless steel 304

800. 0 I
II weight: approx. 50 kg
I
!~
rUN
"
u
I I i
scale: 1: 10
r
'.-----:l:~d
l 345x130 mm
plate
'------
layout
mounting plate
Nots.
IE!l'ffilnal strip XI/X2/X3
X20/X21/X22/X23
SUPpL1C' PHOENIX
Ty p p UK 2,5 N !( G ? ') r~ ,-----~~·-l·
mm' I
i
J"
I I
' T[R
1"'1 minal strip'

IN rl .t.
----
number
.I ':,\I~-,plier·: ' X
179 89B 0
179 886
'II
lj v
iv~)e '~ ! USLKG 5 N

mm' ----
o- - - l
1 7 9 8·-=8-=6-:C
I
222 947 001
----------
253 681 0
-+-~
r!i'>t~111ce /Dmm
100 lOG :l[jU !.JOD 500 600 700 sou

~-~-~~~~~~------,------~---------~---------~--- I
56 INDONESIFl PELRBUHRN VOITH TURBO Ijunct~o~ bOX t Jl n,de, " ____i~__ 001 567=-~-= ,.
1~ K LIDO M Dep all-ea_5~Vlew ~ayou .____3
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13 P
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--l
item no. see oil circuit and measuring pOInt scheme 915 001 198 10
CLIENT
VOl rH
=[J-J'I-~-----== r~~~~~--~==V--S[R
Jll If""1-''P.r"lah1e JumpE'I

5. 0
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I 1---
R 3 4. 1 I
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(> R"IJ
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1",," ---·-·--1
",Il J B LJ
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Voith Turbo I Geared variable speed coupling I SEC 86 Indonesia Pelabuhan I R 15 K 400 M i 2 Parts list
12 Parts list
Drawing
Drawing name I drawing no. Date
group.
04 2010-11-04
-----,---- -----
06 2010-11-04
10 2010,11-04
--~-,- ' ,------,-, ,-,- -,-- - - - - - " , - - , , , - - - , , - - - - - - -
16 20"!0"11-04
17 2010-11-04
---------,------------------,--,-,----------
124
Betriebsanl.-Nr. 91800037910 i
Teileliste zur Betriebsanleitung Operating insLNo
Dcit,
04.11.2010
Parts list for instruction manual Mat .-Nurnmer: 216.000298
~OITH
--
-- M8terial No
Kennwort: Typ: Rev. 00
Reference SEC S 6 Indonesia Pelabuhan Type: I Zeichnungs-Nr. 205005425'10
Rev
Auftrags-Nr. : R 15 K 400 M
lJrawlrlg No
Gruppe ISeite I
Order No.: 38001567 IBlatt:
Sheet
C;roup
04
Page
1/ -.LJ
Zeichnungs-Pos. -N r. Menge ME M aterialnummer Benennung Fremdbenennung Zeichnungsgrp. Ersatzteill ~~l
Drawing item No. Quantity Unit Part. No. Designation Foreign designation Draw ing Group Spare pal ~
00101001010010 ST TCR42259161 Getriebegehaeuse transmission housing 04

00101001010020 ST TCR42259201 Gehaeusedeckel housing cover 04
00101001010030 4 ST TCR03074322 Anschlag-Wirbel swivel n4
0010/0010/0040 10 ST TCR03002391 Sechskantschraube hexagon bolt 04
00101001010050 2 ST TCR03002397 Sechskantschraube hexagon bolt 04
00101001010070 2 ST TCR03002390 Sechskantschraube hexagon boll 04
001010020 1 ST TCR42012310 Zw ischenst ueek intermed. piece 04
001010030 4 ST TCR03008332 Sechskant sell rau be hexagon bolt 04
004010010 1 ST TCR42597130 Ringgehaeuse ring housing 04
011010010 ST TCR42234990 Stirnrad spur gear - 04
011010020 1 ST TCR42235000 Stirnrad spur gear - 04
011010030 6 ST TCR03002150 Sechskantsehraube hexagon boll 04
011010040 1 ST TCR03002293 Sechskantsehraube hexagon bolt 04
011010050 2 ST TCR03130033 Spann-Stitt roll pin 04 C3
012010010 2 ST TCR4223495001 Lagerschale bearing shell 04 81
0120/0020 2 ST TCR03130074 Spann-Stift roll pin 04 C3
012010030 2 ST TCR4225519001 Lagerschale bearing shell 04 81
012010040 2 ST TCR03130073 Spannstift spr. type st r. pin 04 C3
012010050 2 ST TCR42252050 Axiallager thrust bearing 04 B1
012010060 2 ST TCR03049024 Zylinderstift straight pin 04 C3
013010010 1 ST TCR4201209000 Pumpeneinsatz pump insert 04 L1
0130/0020 4 ST TCR03008246 Sechskantsch rau be hexagon bolt 04
015010010 1 ST TCR40725640 Blende orifice plate 04
015010020 1 ST TCR40725640 Blende orifice plate 04
015010030 1 ST TCR.41364940 Blende orifice plate 04
Belriebsanl.-Nr.: 91800037910
I Teileliste zur Betriebsanleitung Operating lnsLNo. Datum
Date
04.11.2010
~OI'H
Parts list for instruction manual Mat .-Nummer: 216.000298
Material No.
Kennwort: Typ: Rev.: 00
Reference
SEC S 6 Indonesia Pelabuhan Type· Zeichnungs-Nr.: 20500542510 Rev.
Auftrags-Nr.:
Order No.
38001567 R 15 K 400 M
Drawing No
Blatt:
Gruppe
Group
ISeite
Page
Sheet· 04 21 7 I
Zeichnungs-Pos.-Nr. Menge ME M aterialnummer Benennung Fremdbenennung Zeichnungsgrp. Ersatzteilkz.

Drawing item No. Quantity Unit Part. No. Designation Foreign designation Draw ing Group Spare part id.
015010040 1 ST 205.00542810 Blende orifice 04

0150/0050 1 ST 205.00203410 Blende orifice 04
0150/0060 1 ST 205.00203210 Blende orifice 04
0150/0070 1 ST TCR03040270 Verschlussschraube screw plug - 04
0150/0080 ST TCR03040248 Verschlussschraube screw plug - 04
015010100 ST TCR40729270 Blende orifice plate 04
0150/0110 1 ST TCR.03040255 Verschlussschraube screw plug - 04
0150/0120 1 ST TCR03658048 Dichtring seal ring 04 C3
0160/0010 ST TCR42437080 Lagerdeckel bearing cover 04
0160/0020 1 ST TCR03645272 Runddichtring o-ring 04 C3
0160/0040 10 ST TCR03002294 Sechskantschraube hexagon bolt 04
0200/0010 1 ST TCR42012720 Schoepfrohrgehaeuse scoop tube housing 04
020010020 1 ST TCR4201299000 Lagergehaeuse bearing housing 04
020010030 3 ST TCR03040270 Verschlussschraube screw plug - 04
020010050 1 ST TCR03646033 Runddichtring o-ring 04 C3
0200/0080 7 ST TCR03014838 Zylinderschraube socket head screw 04
0200/0150 ST TCR.03049010 Zylinderstift st raight pin 04 C3
020010170 ST TCR03049054 Zylinderstift straight pin 04 C3
0210/001010010 1 ST TCR42021220 Primaer-Rad primary wheel 04
0210/001010020 6 ST TCR41906000 Schraube Gew ichtst. weight-tol.screw 04
02101001010030 6 ST TCR41924810 Verbindungsbolzen connecting pin -- 04
BetriebsanL-Nr. 91800037910
Teileliste zur Betriebsanleitung Operating InsLNo. Datum
Date
04.11.2010
Parts list for instruction manual Mal.-Nummer:
~OITH
Material No
216.000298
Reference
SEC S 6 Indonesia Pelabuhan Type Zeichnungs-Nr .. 20500542510 Rev.
Auf! rags-Nr.: 38001567 R 15 K 400 M

Drawing No
Blatt:
Gruppe
Group
ISeite
Page
Order No.
Sheet 04 31 7
Zeichnungs-Pos.-Nr. Menge ME M aterialnummer Benennung Fremdbenennung Zeichnungsgrp. Ersatzteilkz. I

Drawing item No. Quantity Unit Part. No. Designation Foreign designation Draw ing Group Spare part id. I
0210/0010/0040 6 ST TCR.40747310 Schraube Gew ichtst. weight-tol.screw 04

0210/001010045 6 ST TCR.03110008 Federscheibe spring washer 04
0210/0010/0050 ST 205.00570510 Get rieberitzelw elle gear pinion shaft 04
02101001010060 1 ST TCR.42012620 Schale shell - 04
0210/0010/0070 40 ST TCR.40747390 Schraube Gew ichtst. w eight-tol. screw 04
0210/0010/0080 2 ST TCR.41336730 Schmelzsic hergs. Sch rau fusible plug 04 C1
0210/0020 1 ST TCR.42011460 Druckring thrust ring -- 04
021010030 10 ST TCR.03014145 Zylinderschraube socket head screw 04
0220/0010/0010/0010 ST 205.00453510 Sekundaerwelle secondary shaft 04
0220/0010/0010/0010/0030 1 ST TCR.41935520 Gew indestange threaded rod 04
0220/0010/0010/0010/0040 1 ST TCR.42017020 Mutter nut 04
0220/0010/0010/0020 1 ST TCR.42012470 Sekundaerrad secondary wheel 04
0220/0010/0010/0030 ST TCR.42018670 Ring ring 04
022010010/001010040 9 ST TCR.03015032 Zylinderschraube socket head screw 04
0220100101001010050 ST TCR.03130024 Span n-St ift roll pin 04 C3
02201001010020 ST TCR.42221060 Passfeder key 04
023010010 ST TCR.4202031000 Lagerbuchse bearing bush 04 B1
0230/0020 1 ST TCR.03130028 Spannstift spr.type str.pin 04 C3
0230/0030 1 ST TCR.03171120 Sicherungsring circlip 04 C3
0230/0040 1 ST 205.0003410001 Lagerschale bearing shell 04 81
0230/0060 2 ST TCR.42020380 Axiallager thrust bearing 04 81
0230/0070 2 ST TCR.03049024 Zylinderstift st raight pin 04 C3
0250/0010 1 ST TCR.42012920 Zw ischenflansch intermed. flange 04
0250/0015 1 ST H01.068528 Verschlussschraube screw plug - 04
0250/0030 24 ST TCR.03002218 Sechskantschraube hexagon bolt 04
0250/0040 1 ST TCR.42234240 Stuetze support -- 04
T eileliste zur 8etriebsanleitung ==lr:'~~"'~:: ;~; 91800037910
I Datum 04.11.2010
Parts list for instruction manual 216.000298
~OITH
Mal.-Numrner
Kennwort: • Typ:
Matenal No.
IRev.: 00
Reference SEC S 6 Indonesia Pelabuhan Type Zeichnungs-Nr.. 20500542510
IGruppe -----rseite
Rev
Auflrags-Nr.:
Order No.
38001567 R 15 K 400 M I:a~;ng
a .
No.
i 04 I
("OUp Pal)"41 I
Sheet 7 !
Zeichnungs-Pos.-Nr. Menge ME M aterialnummer Benennung Fremdbenennung Zeichnungsgrp. Ersatzteilkz. 1I

Drawing item No. Quantity Unit Part. No. Designation Foreign designation Draw ing Group Spare e.art id. I
025010050 1 ST TCR42234250 Stuetze support -- 04

025010060 22 ST rCR03002220 Sechskantschraube hexagon bolt 04
025010080 2 ST TCR03645284 Runddichtring a-ring 04 C3
025010100 3 ST TCR03014851 Zylinderschraube socket head screw 04
025010110 2 ST TCR42238250 Rohrstueck pipe section - 04
0250/0125 8 ST TCR03100017 Scheibe washer --- 04
0250/0130 6 ST TCR03646108 Runddichtring o-ring 04 C3
0250/0140 2 ST TCR42242420 Flansch flange - 04
025010170 2 ST TCR42239120 Dichtung seal - 04 C3
0260/0010 1 ST TCR42215420 Blende orifice plate 04
0260/0020 1 ST TCR40776390 Blende orifice plate 04
0300/0010 1 ST TCR42238230 Lagerdeckel bearing cover 04
0300/0030 1 ST TCR03645253 Runddichtring a-ring 04 C3
0300/0040 1 ST TCR42238220 Labyrinthscheibe labyrinth disc 04
030010050 1 ST 205.00375910 Schleuderring oil thrower 04
0305/0010 ST TCR03645340 Runddichtring a-ring 04 C3
0310/0010 1 ST 205.00077400 Lagerdeckel bearing cover 04
0310/0040 1 ST TCR42011160 Labyrinthscheibe labyrint h disc 04
I Teileliste zur Betriebsanleitung Belriebsanl.-Nr.:
Operatmg InsLNo .
91800037910 Datum
Date
04.11.2010
rOITH
Parts list for inst ruct ion manual Mat .-Nummer: 216.000298
Material No
Reference
SEC S 6 Indonesia Pelabuhan Type Zeichnungs-Nr.: 20500542510 Rev.
Auftrags-Nr. :
Order No. 38001567 R 15 K 400 M
Drawing No
Blatt:
Gruppe
Group
ISeite
Page
I I Sheet 04 51 7
Zeichnungs-Pos. -N r. Menge ME M aterialnummer Benennung Fremdbenennung Zeichnungsgrp. Ersatzteilkz.

0310/0050 ST TCR03646082 Runddichtring o-ring 04 C3

0310/0060 8T 205.00375510 8chleuderring oil thrower 04
031010070 8 8T TCR03014745 Zylinderschraube socket head screw 04
0315/0010 8T TCR03645282 Runddichtring o-ring 04 C3
0580/0010 1 ST TCR42580220 Oelst andsanzeige oil level indicator 04 L12
058010080 1 ST TCR03658066 Dichtring seal ring 04 C3
0610/0010 1 ST TCR42237180 Oelwanne oil reservoir 04
0610/0020 56 8T TCR03002220 Sechskant sch raube hexagon bolt 04
0610/0030 5 M TCR03661132 Dichl u ngsband sealing tape -- 04
061010050 2 8T TCR03658042 Dichtring seal ring 04 C3
061010060 1 ST TCR03001205 Blindflansch blind flange 04
061010070 ST TCR03660026 Flachdichtring flat seal ring 04 C3
061010080 4 ST TCR03002291 8ec hskant sch rau be hexagon bolt 04
0640/0010 1 ST TCR42013240 Anfahrschmierpumpe start. lube pump 04
065010010 1 8T TCR4188931002 Ent lueft ungs-Filt er vent filter 04
066010010 8T TCR4201043001 Doppelfilter duplex filter 04
068010010 1 8T TCR4260 1190 11 Filterfuss mit Drossel filter base w. t h rott 04
068010020 1 8T TCR42600160 Einstellschraube adjusting screw - 04
068010030 2 8T TCR03658027 Dichtring seal ring 04 C3
0680/0040 1 8T TCR42250240 Mutter nut 04
0680/0050 1 ST TCR40812170 Hutmutter cap nut - 04
0680/0070 8 8T TCR03014745 Zylinderschraube socket head screw 04
0680/0080 8T TCR.42243890 Dichtung seal - 04 C3
0680/0090 2 8T TCR42244720 Dichtung seal - 04 C3
0680/0120 1 ST TCR03000322 SAE-Verschlussflansch SAE sealing flange 04
0690/0010 1 8T TCR42234730 Deckel cover -- 04
Betriebsanl.-Nr.: 91800037910
Teileliste zur Betriebsanleitung Operating msLNo. Datum
Date
04.11.2010
Parts list for instruction manual Mal.-Nummer: 216.000298
VOITM Kennwort:
Reference
Auftrags-Nr. :
SEC S 6 Indonesia Pelabuhan
38001567
Typ:
Type
R 15 K 400 M
Material No
Zeichnungs-Nr.: 20500542510
Drawing No.
Rev.:
Rev.
Gruppe
Group
00
ISeite
Page
Order No. Blatt:
Sheet 04 61 7
I
Zeichnungs-Pos.-Nr. Menge ME M aterialnummer Benennung Fremdbenennung Zeichnungsgrp. Ersatzteilkz. I
0690/0020 1 ST TCR42234740 Deckel cover -- 04

0690/0030 1 ST TCR42234750 Deckel cover -- 04
0710/0010 1 ST TCR4221998002 Motor motor 04 L2
0750/0010 ST TCR03001108 Vorschweissflansch welding-neck flange 04
0750/0020 1 ST TCR03661082 Flachdicht ring flat seal ring 04 C3
0750/0040 1 ST TCR03001108 Vorsc hw eissf lanse h welding-neck flange 04
0750/0050 ST TCR03661082 Flachdicht ring flat seal ring 04 C3
0750/0070 1 ST TCR03001107 Vorschweissflansch welding-neck flange 04
0750/0130 ST TCR03001109 Vorschweissflansch welding-neck flange 04
0750/0170 2 ST TCR03660028 Flachdichtring flat seal ring 04 C3
0750/0190 1 ST TCR0300 1108 Vorschweissflansch welding-neck flange 04
075010200 ST TCR03661082 Flachdichtring flat seal ring 04 C3
0750/0220 1 ST TCR03001207 Blindflansch blind flange 04
0750/0230 ST TCR03660028 Flachdichtring flat seal ring 04 C3
Betriebsanl.-Nr.: 91800037910
Teileliste zur Betriebsanleitung Operating InsLNo Datum
Date
04.11.2010
Parts list for instruction manual Mat .-Nummer: 216.000298
VOITM Kennwort:
Reference:
Auftrags-Nr. :
38001567
Typ:
Type
R15 K400 M
Material No.
Drawing No.
Rev.
Rev.
Gruppe
Group
00
ISeite
Page
Blatt:
Order No.:
Sheet 1 04 71 7
Zeichnungs-Pos.-Nr. Menge ME M aterialnummer Benennung Fremdbenennung Zeichnungsgrp. Ersatzteilkz.

Drawing item No. Quantity Unit Part. No. Designation Foreign designation Drawing Group Spare part id.
0750/0250 1 ST TCR03001207 Blindflansch blind flange 04

0750/0260 1 ST TCR03660028 Flachdichtring flat seal ring 04 C3
0750/0310 4 ST TCR03072017 Sechskantmutter hexagon nut 04
IBetriebsanl.-Nr. 91800037910 --r----
VOITM Kennwort:
Reference:
Teileliste zur Betriebsanleitung
Parts list for instruction manual
SEC S 6 Indonesia Pelabuhan Typ:
Type:
-I Ope rat I ng Inst, No
~;!;,~~~~mer 216.000298
leichnungs-Nr .. 42591420
IDatum
! Date
I
Rev.:
R~v
04.11.2010
00
I
I
Auftrags-Nr.: R 15 K 400 M
I DraWing No
I ~~u~pe ISeite
Order No.: 38001567 IBlatt
. Sheet 06 I
Page
11 4J
-
Zeichnungs-Pos. -N r. Menge ME M aterialnummer Benennung Fremdbenennung Zeichnungsgrp. Ersatzteilkz. I
Drawing item No. Quantity Unit Part. No. Designation Foreign designation Draw ing Group Spare part id. ,
0200/0090 1 ST TCR42013550 Fuehrungsbuchse guide bushing 06 85

020010100 1 ST TCR42013560 Fuehrungsbuchse guide bushing 06 85
020010110 ST TCR41334440 Zylinderschraube socket head screw 06
0240/0010 1 ST TCR42598350 Schoepfrohr rechts scoop tube, cw 06 L13
0240/0010/0020 1 ST TCR42013600 Kolben piston - 06
024010020 1 ST TCR.03646128 Rundd icht ri ng o-ring 06 C3
0240/0030 1 ST TCR42013620 Huelse sleeve 06 L13
0240/0040 1 ST TCR03130011 Spannstift spr.type str.pin 06 L13
0240/0050 1 ST TCR03130076 Spann-St ift roll pin 06 L13
0340/0010 1 ST TCR42208260 Wegaufnehmer displacement pickup 06 86
0340/0020 1 ST TCR42208270 Magnet magnet 06 86
0345/0010 1 ST TCR43827680 Wegeschieber way valve 06 86
0345/0030 2 ST TCR.03130028 Spannstift spr.type str.pin 06 C3
0345/0040 ST TCR42213210 AdapterplaUe adapter plate 06
0345/0060 ST TCR03645020 Runddichtring a-ring 06 C3
0345/0070 1 ST TCR41417080 Messanschluss measuring connect. 06
035010010 1 ST TCR4202287001 Zylinder cylinder 06
0350/0030 5 ST TCR03130028 Spannstift spr.type str.pin 06 C3
0350/0040 1 ST TCR42013610 Zylinderdeckel cylinder head - 06
0350/0050 1 ST TCR03172949 Sprengring snap ring 06 C3
0350/0060 1 ST TCR03646641 Fuehrungsring guide ring 06
0350/0070 1 ST TCR03646623 Quadring Quadring 06 C3
Betriebsanl.-Nr. 9180003791 {)
Teileliste zur Betriebsanleitung Operating InsLNo, Datum
Date
04.11.2010
Parts list for instruction manual Mal.-Nummer:
~OITH
Material No
216.000298
Reference: SEC S 6 Indonesia Pelabuhan Type Zeichnungs-Nr.: 42591420 Rev.
Auftrags-Nr. : 38001567 R 15 K 400 M

Drawing No,
Gruppe
Group
ISeite
Page
Order No. Blatt:
Sheet 06 21 4
Zeichnungs-Pos. -N f. Menge ME M aterialnummer Benennung Fremdbenennung Zeichnungsgrp. Ersatzteilkz.

035010080 6 ST TCR03150003 Gew indebolzen stud bolt 06

035010090 15 ST TCR03072211 Sechskantmutter hexagon nut 06
0350/0100 1 ST TCR42014010 Abdeckung cover 06
0350/0110 ST TCR40412670 Faltenbalg bellows 06 C3
0350/0130 2 ST TCR49950073 Schlauchschelle hose clip 06 C3
0350/0140 1 ST TCR42014360 Halter holder 06
0350/0170 ST TCR42212490 Blech plate 06
0350/0180 ST TCR03002527 Sechskantschraube hexagon bolt 06
0350/0210 1 ST TCR42014020 Fueh rungsst ueck guide piece 06
0350/0230 ST TCR03645009 Runddichtring o-ring 06 C3
0360/0010 ST TCR42013630 Ventildeckel valve cover 06
0360/0040 1 ST H01.054615 Verschlussschraube screw plug - 06
0360/0050 1 ST TCR03172938 Spreng ring snap ring 06 C3
0360/0060 1 ST TCR03646632 Fuehrungsring guide ring 06 C3
0360/0070 1 ST TCR03646618 Quadring Quadring 06 C3
0360/0090 1 ST TCR42014330 Haltering retaining ring 06
0360/0110 1 ST TCR03170059 Sicheru ngsring circlip 06 C3
0360/0120 1 ST TCR03670159 Faltenbalg bellows 06 C3
0360/0140 2 ST TCR49950073 Schlauchschelle hose clip 06 C3
Betriebsanl.-Nr. 91800037910
Teileliste zur Betriebsanleitung Operating Inst.No. Datum 04.11.2010
Date
Parts list for instruction manual Mat.-Nummer: 216.000298
VOITM Kennwort:
Reference
Auftrags-Nr. :
38001567
Typ
Type
R 15 K 400 M
Material No.
Drawing No.
Rev.: 00
Rev.
Gruppe
Group
ISeite
Page
Order No.: Blatt
Sheet: 06 31 4 I
Zeichnungs-Pos.-Nr.
Drawing item No.
Menge
Quantity
ME M aterialnummer
Unit Part. No.
Benennung
Designation
Fremdbenennung
Foreign designation
Zeichnungsg rp.
Drawing Group
Ersatzteilkz.
Spare part id.
I
0360/0150 1 ST TCR42014060 Gew indebolzen stud bolt 06
0360/0170 4 ST TCR03072021 Sechskant mutter hexagon nut 06
0360/0180 1 ST TCR42013490 Flachstueck flat piece 06
0360/0190 ST TCR42013500 Hebel lever 06
0360/0200 4 ST TCR.03094286 Buchse bush 06 C3
0360/0210 2 ST TCR42208240 Bolzen pin 06
0360/0220 4 ST TCR03170028 Sicherungsring circlip 06 C3
0360/0230 1 ST TCR42013510 Hebel lever 06
0360/0240 6 ST TCR03094291 Buchse bush 06 C3
0360/0250 3 ST TCR03094293 Buchse bush 06 C3
0360/0260 1 ST TCR42208160 Bolzen pin 06
0360/0270 6 ST TCR03171025 Sicherungsring circiip 06 C3
0360/0290 2 ST TCR03072211 Sechskant mutter hexagon nut 06
0360/0310 ST TCR42013520 Hebel lever 06
0360/0320 1 ST TCR42 02 7360 Gabelstueck end piece fork 06
0360/0330 2 ST TCR42208110 Bolzen pin 06
0360/0340 ST TCR42014420 Schild nameplate - 06
0360/0350 2 ST TCR03125036 Halbrundkerbnagel round head notched pin 06
0360/0360 1 ST TCR42014440 Gew indebolzen stud bolt 06
0360/0370 ST TCR03072211 Sec hskant m ut t er hexagon nut 06
0360/0380 1 ST TCR03130451 Spann-Stitt roll pin 06 C3
0365/0010 1 ST TCR42027350 Kolben piston - 06
0370/0010 1 ST TCR42015800 Haube hood 06
Betriebsanl.-Nr. 91800037910
Teileliste zur Betriebsanleitung Operating lnsLNo. Datum:
Date:
04.11.2010
Parts list for inst ruet ion manual Mal.-Nummer: 216.000298
VOITM Kennwort:
Reference
Auftrags-Nr.:
38001567
Typ:
Type
R 15 K 400 M
Material No.
Drawing No.
Rev.:
Rev.
Gruppe
Group
00
ISeite
Page
Order No. Blatt:
Sheet 06 I 41 4
Zeichnungs-Pos.-N r. Menge ME M aterialnummer Benennung Fremdbenennung Zeichnungsgrp. Ersatzteilkz.

0700/1.1 1 ST TCR.41426060 Versehraubung fitting --- 06

0700/4.1 1 ST TCR.41720480 Aufsteekstutzen slip-on union 06
0700/5.1 ST TCR.41721710 Aufsteekstutzen slip-on union 06
0700/5.5 1 ST TCR.41721730 W-Versehraubung elbow fitting - 06
0700/6.1 2 ST TCR.41721710 Aufsteckstutzen slip-on union 06
0700/7.1 2 ST TCR.41721710 Aufsteckstutzen slip-on union 06
Belriebsanl.-Nr. 91800037910 04.11-.201-0---]
Teileliste zur Betriebsanleitung Operating If]st .No Datum
Oate
P=-:a=:.rt..:..:s:.......:.:.;lis:..:t~f:...=o..:._r._:.;in:. :.:s:.: .t:. : :ru:. : :c.: . ;.i.=..on~m:..:.:a::;:-n:..:::u:...=a~1--.-~-----l Material 216.000298 1 - - '
~OITH
t M al.-Nummer
I
r-
________
Kennwort: SEC S 6 Indonesia Pelabuhan Typ:

No
Rev
Rev .. 00 II
Reference: Type Zeichnungs-Nr.: 42012090
J
Drawing No
Auflrags-Nr.:
Order No.
38001567 R15K400M I Blatt:
i Sheet 2
Zeichnungs-Pos. -N r. Menge ME Materialnummer Benennung Fremdbenennung Zeichnungsgrp. Ersatzteilkz. I

Drawing item No. Quantity Unit Part. No. Designation Foreign designation Drawing Group Spare part i~
0130/0010/0010 1 ST TCR42012000 Lagergehaeuse bearing housing 10

0130/0010/0020 4 ST TCR03039017 Verschlussschraube screw plug - 10
0130/0010/0025 2 ST TCR40795460 Blende orifice plate 10
0130/0010/0030· 1 ST TCR42011990 Pumpengehaeuse pump housing 10
0130/0010/0040 3 ST TCR03002064 Sechskantschraube hexagon bolt 10
0130/0010/0050 3 ST TCR03645180 Runddichtring o-ring 10 C3
0130/0010/0060 1 ST TCR42012160 Zw ischenst ueck intermed. piece 10
0130/0010/0070 3 ST TCR03014069 Zylinderschraube socket head screw 10
0130/0010/0080 1 ST TCR42012070 Antriebswelle drive shaft 10
0130/0010/0090 1 ST TCR42207640 Lagerbuechse bearing bushing 10 82
0130/0010/0100 1 ST TCR03048022 Gewindestift grub screw 10
0130/0010/0110 1 ST TCR42012200 Bundlager collar end bearing 10 82
0130/0010/0120 ST TCR42012190 Einstellscheibe adjusting disc - 10
0130/0010/0140 1 ST TCR42012150 Kegelradpaar pair of bevel gears 10
0130/0010/0150 1 ST TCR42182650 Obere Lagerbuechse top bearing bush 10 B2
0130/0010/0160 1 ST TCR03130022 Spann-St itt roll pin 10 C3
0130/0010/0170 1 ST TCR03166170 Passscheibe shim 10 C3
0130/0010/0180 1 ST TCR03166171 Passscheibe shim --- 10 C3
0130/0010/0190 1 ST TCR42012180 Pumpenwelle pump shaft 10
0130/0010/0200 1 ST TCR40716490 Fuellpumpen lauf rad filler pump impeller 10
0130/0010/0210 1 ST TCR03160078 Passfeder key 10
0130/0010/0220 1 ST TCR42012170 Haltescheibe holding disc 10
0130/001010240 3 ST TCR42011670 Gleitlager plain bearing 10 82
01301001010270 1 ST TCR42012260 Bundbuchse collar bushing 10 B2
~ MaL-Nummer
BetriebsanL-Nr.: 91800037910
Teileliste zur Betriebsanleitung Operating IllsLNo I patum 04.11.2010
;~e
1
~
Parts list for instruction manual 216.000298
OITH Kennwort:
Reference SEC S 6 Indonesia Pelabuhan I ilte:
- I Malenal No
I 42012090
I Rev ..
Rev
00
Seite
I
.
Auf! rags-Nr.:
Order No.: 38001567 R15 K400 M iI Blatt.
Sheet
Page
21 2
I
Zeichnungs-Pos. -N r. Menge ME M aterialnummer Benennung Fremdbenennung Zeichnungsgrp. Ersatzteiikz. I

Draw ing item No. Quantitv Unit Part. No. Designation Foreign designation Draw ing Group Spare part idJ
0130/0010/0280 3 ST TCR40170810 Planetenritzel planet pinion 10

013010010/0290 1 ST TCR40170800 Ritzel pinion 10
013010010/0300 ST TCR03160042 Passfeder key '! 0
.~
Betriebsanl.-Nr 91800037910
Teileliste zur Betriebsanleitung Operating l!lst,No Datum (]
Date
Parts list for inst ruct ion manual Mal.-Numrner: 216.000298
VOITM Kennwort:
Reference:
Auftrags-Nr. :
38001567
Typ:
Type
R15 K400 M
Material No
I Zeichnungs-Nr
Drawing No
42453070
Rev.
Rev
Gruppe
Group
00
-~--I
I Selle
i Paq()
Order No.: I S'leet
Blatt. 16 i 1t 1 ;
-
IZeichnungs-Pos.-Nr. Menge ME M aterialnummer 8enennung Fremdbenennung Zeichnungsgrp. Ersatzteilkz.
Drawing item No. Quantity Unit Part. No. Designation Foreign designation Draw ing Group Spare part id
0020/0010 1 ST TCR42010480 Ventilkolben valve piston - 16 86

002010020 1 ST TCR41768860 Einstelischraube adjusting screw - 16
0020/0030 ST TCR03210108 Druckfeder compression spring 16 C3
0020/0050 1 ST TCR03658064 Dichtring seal ring 16 C3
Teileliste zur Betriebsanleitung
Parts list for instruction manual
I Belriebsanl.-Nr.:
Operat Ing inst No
91800037910
216.000298
------r
~,~~"m 04.11.201 0 ~
I
OI'H Kennwort:
Reference:
Auftrags-Nr.:
Order No ..
38001567
I +/p~:
I R 15 K 400 M
I
Blatt·
42453060
%ppe
Rev.
Rev
! ~c~~p
00
17
Seile
r'age 1i 1
l
J
I Sheot
------------------------~,
Zeichnungs-Pos.-Nr. Menge ME Materialnummer Benennung Fremdbenennung Zeichnungsgrp. Ersatzteilkz. Ii
Drawing item No. Quantity Unit Part. No. Designation Foreign designation Draw ing Group Spare part id ..
003010010 1 ST TCR42010480 Ventilkolben valve piston - 17 86

0030/0020 1 ST TCR41768860 Einstellschraube adjusting screw - 17
0030/0030 1 ST TCR42453050 Zyl. Druckfeder cyLcornpr spring 7 C3
0030/0040 1 ST TCR.40378300 Verschlussschraube screw plug - 17
0030/0050 ST TCR03658064 Dichtring seal 17 C3
VOITH
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R i 5 K 400 M 13 Recommended spare parts list
13 Recommended spare parts list
13.1 Use I installation of genuine Voith spare parts
Genuine Voith spare parts have been designed specifically for use with the Geared
variable speed coupling. We would like to point out that original spare parts that are
not supplied by "VOITH" are also not checked and approved by us. Installation and/or
use of non-original spare parts may adversely affect the design characteristics of the
Geared variable speed coupling, thus compromising safety.
"VOITH" does not assume any responsibility for damage arising from the use of non
original spare parts.
13.2 Spare parts identification
Spare parts are classified Into groups.
Spare parts identification:
• C Parts for commissioning

B Parts for maintenance
• L Parts for long-term operation
Item nos. in a drawing (e.g. 0210/0010/0040) that appear in the spare parts list
without an associated drawing group (e.g. 04) me not itemized in the drawings
and parts lists (see and
. ).
c
2
125
VOITH
Voith Turbo I Geared variable speed coupling I SEC 86 Indonesia Pelabuhan I R 15 K 400 M 13 Recommended spare parts list
Original spare parts are supplied on the basis of the latest level of technology. Ordering spare
parts
We thus suggest that the spare parts in the recommended spare parts list be stored
on site.
Gears may be replaced in sets only. Please send still usable shafts to Voith
Crailsheim for joint assembly and balancing with the gears.
The primary wheel and secondary wheel are balanced together with the shafts
and the shell using a special balancing procedure. Therefore, these
components can be replaced only at Voith Crailsheim or, in exceptional cases,
under the supervision of a Voith service engineer on site using special auxiliary
means.
13.3 Ordering spare parts
When ordering spare parts, please indicate:
1. Serial number of the Geared variable speed coupling (see nameplate) Geared va
riable speed coupling
2. Full designation such as
- Drawing item no.
- Material/Article No.
Part name (designation)
- Quantity
c
o
~
>
126
Kennwort SEC S 6 Indonesia Pelabuhan Voith Turbo GmbH & Co.KG
Ersatzteilliste Obersicht Code:
Voithstra[l.e 1
OITM Survey of Spare Parts Lists
SAP Angebots-Nr· 20141073

Typ:
Type:
Serien Nr.
R 15 K 400 M
8204536, 8204537, 8204538

74564 Crailsheim, Germany
Tel. +49 7951 32-1666
Fax +49 7951 32-903
SAP Offer No.: Serial No .. coupling-service@voith.com
Lieferumfang: 216.000298 Betriebsa nl.-Nr.: www_voith-couplinn-s8rvice.com
91800037910
Scope of supply: Instruction Manual No.: DatumlDate 2010-11-08 Rev.No: 0
._-----
C = Teile fUr Inbetriebnahme Commissioning ~arts

C1 1 Satz I set Schmelzsicherungsschrauben of fusible plurjs
C2 1 Satz set Filterelemente I of filter elements
C3 Satz set Dichtungs- und Revisionsteile aligemein service kit with a set of sea lings
B = Ersatzteilgrundausstattung Basic s~are parts

B1 1 Satz / set Hauptwellenlager oder Nadellager fUr Wandler I of main shaft bearings or needle bearings
B2 Satz I set Lager zur HauptfOlipumpe of bearings for main filling pump
B4 Satz / set Lager zur Anfahrschmierpumpe ASP of bearings for aux.lube oil pump
B5 Satz set SchbpfrohrfUhrungsbOchsen / of scoop tube guide bushes
B6 Satz set Teile fUr VEHS und Steuerungsteiie I of parts for electro-hydraulic positioning control make Va it
L = Ersatzteile fur Langzeitbetrieb long term s~ar!L.Q?rts

l1 1 Stock / off HauptfOlipumpe / main filling pump
l2 Stock I off Anfahrschmierpumpe (ASP) plus 1 Motor aux. iube oil pump plus 1 motor
l5 Satz / set Primarlauferteile I of runner parts
l6 Satz I set Sekundarlauferteile I of secondary runner parts
l12 Satz I set Anbauteile fOr Druck-, Schwingungs-, Drehzahl- und Temperatu components for pressure, vibration, turn, temperature m
L13 Stock I off Schbpfrohr / scoop tube
Page 1 of 9
Kennworl: SEC S 6 Indonesia Pelabuhan Voith Turbo GmbH & Co.KG
ErsatzteiIIiste Obersicht Code:
Voilhstraf.l.e 1
~OITH Survey of Spare Parts Lists Typ: R 15 K 400 M 74564 Crailsheim, Germany
Type: Tel. +49 7951 32-1666
SAP Angebols-Nr.: 20141073 Serien Nr. 8204536, 8204537, 8204538 Fax +49 7951 32-903
SAP Offer No.: Serial No.: coupling-service@voith.com
-
Lieferumfang:
Scope of supply:
216.000298 Betriebsanl.-Nr.: 91800037910 www.voith-coupling-service.com I
Instruction Manual No.: Datum/Datp: 2010-11-08 Rpv.No: 0
- -
Brief instructions for spare parts enquiries or spare parts orders
Item No. The drawing item number is indicated in the spare parts offer/order position, enabling a clear allocation of parts
to the items stated in the spare parts lists and the drawings of the instruction manual.
Quantity Determines the quantity of parts installed in the unit.
Unit Physical unit of the material used per article number.
Part No. Voith Material No.
Designation Designation of material in SAP.
Drawing Group Indicates the numbering of the drawing in which the part with the appropriate drawing item number is
contained.
Spare part id. The spare part identification classifies the spare parts in groups for which corresponding recommendations
for spare parts storage can be made by the Voith Coupling Service . Upon request, the Voith Coupling Service
prepares individual spare parts proposals for every project with one or several units.
o
Selection By ticking, one or several articles are being selected on item level for which an offer or an order
confirmation for spare parts needs to be prepared. It is omitted if the field "all items" was ticked and selected.
o
t..D.lli!irY Selection for enquiry initiating the preparation of a spare parts offer.
Order Selection for order initiating the preparation of an order confirmation.
All items By ticking, all Items with the corresponding identification are selected for which an offer or an order
confirmation needs to be prepared. if individual items are selected, that field has to remain blank.
Page 2 of 9
Kenflwort: SEC S 6 Indonesia Peiabuhan Voith Turbo GmbH & Co.KG
Ersatztei IIiste Obersicht Code:
f--- Voithstral',e 1
¥OITH Survey of Spare Parts Lists
SAP Angebots-Nr.: 20141073

Typ:
Type:
Serien Nr
R 15 K 400 M
8204536, 8204537, 820453B

74564 Crailshelnl. Germany
Tel. +49 7951
Fax +49 7951
32-1666
32-903
SAP Offer No.: Serial No .. coupling~sorvice@voith.com
Lieferumfang: 216.000298 Belr1ebsanl.-Nr www.voith--coupiing-service.com

91800037910
Scope of supply: Instruction Manual Nc.· Oatum/Oilt,,: 2010-11-08 Rev.No 0
C = Commissioning parts Anfrage/Ellquiry o Bestellung/Order DAile Positiollen/AIl items
Zeichnungs-Pos.Nr. Menge ME Materialnummer Benennung Zeichnungsgrp. Ersatzteilkz. Auswah!

Item No. Quantity Unit Part. No. Designation Drawing Group Spare part id. Selection
021010010/0080 2 ST TCR,41336730 fusible plug 04 C1 0

0650/0010/0010 1 ST TCR,4188931007 iilter element C2 n
LJ
0660/0010/0010 2 ST TCR,42218810 filter element C2

002010030 ST TCR.0321 01 08 compression spring 16 C3
002010050 1 ST TCR.03658064 seal ring 16 C3 0
003010030 ST TCR,42453050 cyl.com pr.spring 17 C3 0
003010050 ST TC R .03658064 seal ring 17 C3 0
00401001010030 ST TC R .036580 14 seal ring C3 0
011010050 2 ST TCR.03130033 roll pin 04 C3 0
0120/0020 2 ST TCR.03130074 roll pin 04 C3 0
012010040 2 ST TCR.03130073 spr.type slr.pin 04 C3 0
012010060 2 ST TCR.03049024 straight pin 04 C3 0
01301001010050 3 ST TCR.03645180 a-ring 10 C3 0
01301001010160 ST TCR.03130022 roll pin 10 C3 0
..... h: ___
013010010/0170 1 ST TCR.03166170 ;:, 111111 10 C3 0
0130/001010180 ST TCR.03166171 shim -- 10 C3
0150/0120 ST TCR.03658048 seal ring 04 C3
015010140 ST TC R .036580 17 seal ring C3 0
0150/0160 ST TCR.03658028 seal ring C3
0160/0020 ST TCR.03645272 o-ring 04 C3
020010050 ST TCR.03646033 a-ring 04 C3 0
0200/0150 ST TCR.03049010 straight pin 04 C3 0
020010170 ST TCR.03049054 straight pin 04 C3 0
0200/0190 ST TCR.03656017 seal ring C3
Page 3 of Q
Ersatzteilliste Ubersicht Code:
Voithstrafl,e 1
lVOITH Survey of Spare Parts Lists

Typ:
Type:
Serien Nr.
R 15 K 400 M
8204536, 8204537, 8204538

Tel. +49 7951 32-1666
Fax +49 7951 32-903
Licferumfang: 216.000298 Bclrlcbsanl.-Nr.: www.voith-coupling-service_corn
91800037910
Scope of supply: Instruction Manual No.: Datum/Oat": 2010-11-08 <-<"v.No: 0
------------- -------,.
C = Commissioning parts Anfrage/Enquiry o Bestellung/Order DAile PositioneniAl1 items 0

Zeichnungs-Pos.Nr. Menge ME Materialnummer Benennung Zeichnungsgrp. Ersatzteilkz. Auswahl
0200/0220 8T TCR,03646042 o-ring 06 C3 0

0220/001 % 0 10/0050 8T TCR.03130024 roll pin 04 C3 D
023010020 8T TCR.03130028 spr.type str.pin 04 C3 D
023010030 8T TCR.03171120 circlip 04 C3 0
0230/0070 2 8T TCR.03049024 straight pin 04 C3 0
024010020 1 8T TCR.03646128 a-ring 06 C3 0
0250/0080 2 8T 1CR.03645284 a-ring 04 C3 0
025010090 3 8T TC R .03645036 o-ring 04 C3 0
025010130 6 8T TCR.03646108 a-ring 04 C3 0
0250/0170 2 8T TCRA2239120 seal - 04 C3 0
030010030 8T TCR.03645253 o-ring 04 C3 0
0300/0060 1 8T TC R .03646122 o-ring 04 C3 0
0305/0010 1 8T TC R .03645340 o-ring 04 C3 0
0310/0030 8T TCR.03645169 o-ring 04 C3 0
0310/0050 8T TCR.03646082 o-ring 04 C3 0
0315/0010 1 8T TCR.03645282 a-ring 04 C3 0
0345/0010/290 5 8T TCR.03646146 o-ring C3 0
0345/0030 2 8T TC R .03130028 spr.type stLpin 06 C3 0
0345/0060 1 8T TCR03645020 o-ring 06 C3 0
0350/0020 2 8T TCR03645145 o-ring 06 C3 0
0350/0030 5 8T TCR.03130028 spr.type str.pin 06 C3 0
035010050 8T TCR03172949 snap ring 06 C3 0
0350/0070 8T TCR.03646623 Quadring 06 C3 0
0350/0110 ST TCR.40412670 bellows 06 C3 0
Page 4 of 9
Kennwort: SEC S 6 Indonesia Pelabuhan Voith Turbo GmbH & Co. KG
VoithstraGe 1
Type:
Tel. +49 7951 32-1666
SAP Angebots-Nr.: 20141073 Serien Nr. 8204536, 8204537, 8204538 Fax +49 7951 32-903
SAP Offer No.: Serial No.: coupJing-service@voith.com
Liererumfang: 216,000298 8etriebsanl.-Nr,: www,voith-coupllflg-servicecom
91800037910
Scope of supply: Instruction Manual No,: DalumlDate: 2010-11-08 Rev,No: 0
- - -
C = Commissioning parts Anfrage/Enquiry o Bestellung/Order DAile Positionen/AIi items 0

Zeichnungs-Pos.Nr. Menge ME Materialnummer Benennung Zeichnungsgrp. Ersatzteilkz, Auswahl
Item No, Quantity Unit Part. No. Designation Drawing Group Spare part id. Selection
0350/0130 2 8T TCR,49950073 hase clip 06 C3 0

0350/0230 8T TCR,03645009 a-ring 06 C3 0
0360/0020 8T TCR.03645115 a-ring 06 C3 0
0360/0030 8T TCR,03646006 a-ring 06 C3 0
0360/0050 8T TCR,03172938 snap ring 06 C3 0
0360/0060 8T 1 CR,03646632 guide ring 06 C3 0
0360/0070 8T TCR,Q3646618 Quadring 06 G3 0
0360/0100 8T TCR,03645022 a-ring 06 C3 0
0360/0110 8T TCR,03170059 circlip 06 C3 [J
0360/0120 8T TCR.03670159 bellows 06 C3 0
0360/0140 2 8T TCR,49950073 hose clip 06 C3 0
0360/0200 4 8T TCR,03094286 bush 06 C3 0
0360/0220 4 ST TCR.03170028 circiip 06 C3 0
0360/0240 6 8T TC R .03094291 bush 06 C3 0
0360/0250 3 8T TC R .03094293 bush 06 C3 0
0360/0270 6 ST TCR03171025 circlip 06 C3 0
0360/0380 1 ST TC R .03130451 roll pin 06 C3 0
0520/0035 4 ST TC R036250 18 fiber seal C3 0
0520/0230 2 ST TCR,03658021 seal ring C3 0
0530/0040 2 8T TCRA9914000 ca peelement C3 0
0530/0050 2 ST TCR,42588010 Panel mount C3 0
0550/0055 4 8T TCR.03658028 seal ring C3 0
0580/0080 S1 TCR,03658066 seal ring 04 C3 D
0610/0050 2 ST TC R .03658042 seal ring 04 C3 0
Page 5 af 9
Kennwort: SEC S 6 Indonesia Pelabuhan Voith Turbo GmbH & Co.KG
Ersatzteilliste Obersicht Code:
Voithstra[l.e 1
rvOITH Survey of Spare Parts Lists

Typ:
Type:
Serien Nr.
R 15 K 400 M
8204536, 8204537, 8204538

Tel. +49 7951 32-1666
Fax +49 7951 32-903
SAP Offer No.: Serial No.: coupling-se rvice@)voith.com
Litderumfang: 216.000298 Betricbsclnl.-Nr.: www.voith-coupling-service.co!l1
91800037910
Scope of supply: Instruction Manual No.: Datum/Date;: 2010-11-08 r'ev.No: 0
- ------
G = Commissioning parts Anfrage/Enquiry o Besteliung/Order DAile Positionen/AIl items 0

Zeichnungs-Pos.Nr. Menge ME Materiainummer Benennung Zeichnungsgrp. Ersatzteilkz. Auswahl
0610/0070 ST TC R .03660026 flat seal ring 04 C3 D

0640/0010/0010/10 4 ST TCR.4201316006 seal ring C3 D
0640/0010/0010/11 1 ST TCR.4201316004 shaft seal ring C3 D
0640/0010/0010/12 2 ST TCR.4201316005 a ring C3 D
0640/0010/0010/6 1 ST TCR.4201316003 o ring C3 0
0660/0010/0020 2 ST TCR03645014 o-ring C3 0
0660/0010/0030 2 ST TCR03645167 o-ring C3 0
0660/0010/0040 2 ST TCR03646124 a-ring C3 0
0660/0010/0050 1 ST TCR.03646024 a-ring C3 0
0660/0010/0060 2 ST TCR.03645115 a-ring C3 D
0660/0010/0070 ST TC R .03645195 a-ring C3 D
0660/0010/0080 1 ST TCR.03645121 a-ring C3 D
0660/0010/0090 2 ST TCR.03645168 a-ring C3 D
0660/0010/0100 4 ST TCR.03656014 seal ring C3 D
0660/001010110 2 ST TCR.03658018 seal ring C3 0
0680/0030 2 ST TCR.03658027 seal ring 04 C3 D
0680/0080 1 ST TCR.42243890 seal - 04 C3 D
0680/0090 2 ST TCR,42244720 seal - 04 C3 D
0680/0110 2 ST TCR.03658028 seal ring C3 D
072010030 2 ST TCR03660509 flat seal ring C3 D
0750/0020 1 ST TCR.03661082 Hat seal ring 04 C3 D
0750/0050 ST TC R .03661082 flat seal ring 04 C3 D
0750/0080 2 ST TCR.03660028 flat seal ring 04 C3 D
0750/0110 ST TC R .03661083 flal seal ring 04 C3 D
Page 6 of 9
Kennwort: SEC S 6 Indonesia Pelabuhan Voith Turbo GmbH & Co. KG
Ersatzteill iste Obersicht Code:
Voilhstral1e 1
OITH Survey of Spare Parts Lists

Typ:
Type:
Serien Nr.:
R 15 K 400 M
8204536, 8204537, 8204538

74564 Crailsheim. Germany
Tel. +49 7951 32-1666
Fax +49 7951 32-903
SAP Offer No.: Serial No. coupling-so rvico@voith.com
I ieferumfang: 216.000298 BeiCicbsanL-Nr.: www.voith-coupling-serv!ce.com
91800037910
Scope of supply: Instruction Manual No.: OatumfDate 2010-11-08 Rev.No: 0
C = Commissioning parts Anfrage/Enquiry o Besteliung/Order DAile Positionen/AIl items 0

Zeichnungs-Pos.Nr. Menge ME Materiainummer Benennung Zeichnungsgrp. Ersatzteil kz. Auswahl
075010140 ST TCR.03661083 flat seal ring 04 C3 0

075010170 2 ST TCR.03660028 flat seal ring 04 C3 0
0750/0200 1 ST TCR.03661082 flat seal ring 04 C3 0
0750/0230 1 ST TCR.03660028 flat seal ring 04 C3 0
0750/0260 1 ST TCR.03660028 flai seal ring 04 C3 0
0750/0290 ST TCR.03661082 flat seal ring 04 C3 0
Page 7 of 9
Kennwort· SEC S 6 Indonesia Pelabuhan Voith Turbo GmbH & Co. KG
Ersatzteill iste Obersicht Code:
Voithstraf1,e 1
Type:
TeL +49 7951 32-1666
SAP Angebots-Nr.: 20141073 Serien Nr.: 8204536, 8204537, 8204538 Fax +49 7951 32-903
Lieferumfang: 216.000298 Betriebsanl.-Nr.: www.voith-coupling-service . com
91800037910
Scope of supply: Instruction Manual No.: DatumlDate: 2010-11-08 Rev.No: 0
B ::: Basic spare parts Anfrage/Enquiry o Besteliung/Order DAile Positionen/AIl items D

0120/0010 2 ST TCR,4223495001 bearing shell 04 B1 D

0120/0030 2 ST TCR,4225519001 bearing shell 04 B1 0
0120/0050 2 ST TCR,42252050 thrust bearing 04 B1 0
0230/0010 ST TCR,4202031000 bearing bush 04 B1 0
0230/0040 ST 205.0003410001 bearing shell 04 B1 D
0230/0060 2 ST TCR,42020380 thrust bearing 04 B1 D
0130/001010090 ST TCR,42207640 bearing bushing 10 B2 D
0130/0010/0110 ST TC R ,420 12200 collar end bearing 10 B2 D
0130/0010/0150 ST TC R ,42182650 top bearing bush 10 82 D
0130/0010/0240 3 ST TCR,42011670 plain bearing 10 B2 0
0130/0010/0250 ST TC R ,420 12300 plain bearing 10 B2 D
0130/0010/0260 3 ST TCR,42012230 plain bearing 10 82 0
0130/0010/0270 ST TC R .420 12260 collar bushing 10 B2 D
0640/0010/00101 STZ TCR,4201316001 plain bearing B4 D
0200/0090 ST TCR,42013550 guide bushing 06 B5 D
0200/0100 ST TC R .420 13560 guide bushing 06 B5 0
0020/0010 ST TCR,42010480 valve piston - 16 B6 0
0030/0010 ST TC R ,420 10480 valve piston - 17 B6 0
034010010 ST TCR.42208260 displacement pickup 06 B6 0
0340/0020 ST TCR,42208270 magnet 06 86 0
0345/0010 ST TC R ,43827680 way valve 06 B6 D
055010010/0020 9 ST TCR,42215150 resist. thermometer B6 0
0550/002010020 5 ST TCR,42215150 resist. thermometer B6 D
Page 8 of 9
Voithstra(l,e 1
~OITH Survey of Spare Parts Lists Typ: R 15 K 400 M 74564 Crailsheim. Germany
Type:
1 el. +49 7951 32-1666
SAP Angebots-Nr.: 20141073 Serien Nr. 8204536, 8204537, 8204538 Fax +49 7951 32-903
SAP Offer No .. Serial No.: coupling-service@voith.com
Licferumfang: 216.000298 Bclrlcbsanl.-Nr.: www.voith-coupling-service.com
91800037910
Scope of supply: Instruct!on Manual No.: Datum/Date: 2010-11-08 Rev.No: 0
L = Long term spare parts Anfrage/Enquiry o Besteliung/Order DAile Positionen/Al! items 0

013010010 ST TCR.4201209000 pump insert 04 L1 0

0640/0010/0010 ST TCR.42013160 gear pump L2 0
06401001010020 1 ST TCR.42013230 connecting coupling L2 0
0710/0010 1 ST TC R .4221998002 motor 04 L2 0
0100/0010 1 ST 205.00543310 gear stage- input 04 L5 0
010010020 ST TCR.03160359 key 04 L5 0
0210/0010 1 ST 205.00543110 prim.part, assembly L5 0
0220/0010 1 ST 20500581710 balancing unit L6 0
0520/0030 2 ST TCR.42014770 pressure gauge --- L12 0
058010010 ST TCR.42580220 oil level indicator 04 Li2 0
0665/0010 ST TC R .42448220 contam.indicator Li2 0
024010010 ST TCR.42598350 scoop tube, cw 06 L13 0
0240/0030 ST TCR.42013620 sleeve 06 L13 0
0240/0040 ST TCR.03130011 spr.type str.pin 06 L13 0
0240/0050 ST TCR.03130076 roll pin 06 L13 0
Page 9 of 9
VOITH
Voith Turbo I Geared variable speed coupling I SEC 86 Indonesia Pelabuhan I R 15 K 400 M 14 Attaching parts
14 Attaching parts
14.1 Resistance thermometer
Voith Article No: 20500445410
14.1.1 Resistance thermometer
Vojth Article No.: 20500445510/20500445610
2 x PT 100, 3-wire system
for bearingsi - 10,
Lube oil temperature upstream and downstream of the heat exchanger
and working oil temperature upstream and downstream of the heat ex
changer
Drawing ...... ........ . .......................... 42035240
Description ....... , ........ , , , . , , . , .. , , , . , . . 42/10-20 DE Rev. 2.0
14.1.2 Connection head
Voith Article No.: 4203470002
Type BUZ
Degree of protection: IP 65
Terminal block, 6-pole
m
r-
'"oo
o
<Xl
0;
c
.c
D
~ 127
---_ ... _ -
I-~,--------,~~- --'---------'--------'--~ --.' _5_ _ _ _ -.l__.. _____ _J

Anschlusskopf BUZ
-1
Schulzar! IP65 Elektrlscher Anschluss
Kobelverschraubung M20xl,5
CONNECTING HEAD BUZ I
PROTECTION IP6S ELECTRIC CONNECTION hutzrohr II

CABLE GLAND M20xl,5 ma x. Loenge 800rrm
I (kann gekuerzt werden)
~~--.- -----~-~------------------
PROTECTIVE PIPE
~'I~l
~
MAX. LENGTH 800rnnn
(CAN BE ADAPTED) Fe~.erweg II '
l~ '1
Sockel ; 6 Anschlussklemnen
BASE 6 CONNECTING TERMINALS
,
I ..._~= ,
/IDISTANC[
OF SPR ING i [I
3 uO::::
'I Verschroubung mil Locll Ie 572 obgedlchtel
r>~-
r 0-
0-
<r::
/'
/PiPE UNION DEALED WITHLOCTITE 572
/
Feder
SPRiNG \
II \
I I '
! j
I, ,! co
Messvorrichtung mit
I~
D
c RTD 2x PIIOO ; 3 Lei ter-System

DIN IEC 751 KI.B
MEASUR ING ELEMENTWITH
" I
Klemmverschraubu
-- RTD 2x PIIOa ; 3 WIRE SYSTEM
r
_. --------
DISPLACEABLE PRESSURE FITTING OiN lEe 751 KL.B

Einbouloellge
k---- -----
U.I D LENGTH
J
'i I c c
I, Div.2, Group C & D;
CD@ Class
Temperature Code 15
Federbelastetes oeldlchtes Widerslondslhermomeler

_va r h_~nde.ne Sp r oc he!1J~vo i Io~~!e langUage] . 2xPtl00 ; 3 Leiter-System
[
de I en I Ir I pi
- - - ------ .,-------
------ ------
~ SPRING-LOADED OILTIGHT RESISTANCE THERMOMETER
,'" I B
2xPtl00 ; 3 WIRE SYSTEM
Prueff"'d~I~~g~r 'r Ze,shnuil9~~ nach VN P;,',i
-VN--"-- ,
,~
;; =---~
-w Bes.tel- i;?i;f'.'l ("I rift
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~Ia:
Massslab 1m Or ig.
~~ .... " "jW '9
.~~ U
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~O
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~(L
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_-----!
...ceo
Werksto1f) Wer~s!ojf-~lr.
'<3:
""""'-,"0\,,'0' ,',"N. No, '" i>gh;;\hii-Hr. Rohtl.P~eH1(J(hil",P,t. 1
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mil
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"SO",, "Wi ders t on
. - d("" t ,lie rm .
----I -+- f-
RESISTANCE THERMOM.
II Ix
Aend~rUil9
Roe: h F , \:7@IO'iJ'1ii] 'ifM~I!(,,)
I ANTRIEBSTECHNIK 4 203524
/ Sorh-Nr _
6° [J
PO
><' 1"1N0 deen
~;;, Ils~1 hI Rfl (,hop Qnd en9. InlQ onl~) I ~: CAD 1~f~;4221772 0-· ----------i-Trt--T------- i,~ ~ ~--~
--.:
Thermocoupies Installation and maintenance
Resistance thermometers
Operating manual 42/10-20 EN Rev. 2.0

Contents
Page Seite
1. General 2 6. Maintenance 4
2. Thermocouples 2 7. Troubleshooting 5
7.1 Quick Check 5
3. Resistance Thermometers 2 7.2 Error Table for Thermocouples and
Resistance Thermometers 5
4. Thermometers with head-mounted Transmitter. 3
8. Wiring diagram and color coding 7
5. Mounting and Operation
Installation ..
5.1 3
5.2 Connecting wires 3
5.3 Instructions for explosion prooved Components 4
5.4 Protection Tubes ...... . 4
1. General
We are capable of supplying complete thermometer assemblies On receiving the thermometer assembly, please make sure to
ready for immediate use. unpack all supplied articles, including those that may be deli
vered in dismantled form.
These thermocouples or resistance thermometers are sensitive
devices which contain either glass or ceramic parts. They must long thermometers must be supported at various points, and
therefore be handled with due care, lifted up or transported in appropriate manner, The same care
must be taken during the actual installation of the device. Prior
to installation, please check the thermometers (see 5.1) to en
sure that the device has suffered no transportation damages.
2. Thermocouples
Thermocouple assemblies are delivered with 1, 2, or sometimes The connection ofthe thermocouple to the measuring instrument
3 thermocouple elements. The measuring point is usually insu is established with a compensation lead (Cl). Only the right type
lated but can still be connected to the protecting tube. of compensation leads suiting the thermocouple and possessing
the right polarity should be used for the connection. The leads
should be at least 0.5 m away from the power cables, preferably
laid in their own cabletrays. Twisted and shielded cables sup
press magnetic and electrical parasitical interferences.
3. Resistance Thermometers
Resistance thermometers are supplied with 1, 2, or sometimes Conventional copper cables usually found on the market, prefer
with 3 measuring resistors. ably with 1.5 mm L cross-section should be laid, possibly at about
0.5 m away from the power cables, at best on their own cable
The measuring point is isolated. The connection between resis
trays,
tance thermometer and measuring instrument is mostly of the 2
wire type (the sum and compensation of line resistance become Twisted and shielded cables suppress magnetic and electrical
part of the measurement). To obtain accurate measurements, the parasitical interferences.
3-wire technique is used. If highly accurate measul'ements are
Depending on the type, care must be taken not to exceed the
desired, the 4-wire technique with constant current and high
measuring currents of 0.1 to 10 mA, recommended by the manu
resistance voltage pick-up are used.
facturer (errors may result from inherent heating).
2
4. Thermometer with head-mounted Transmitter
The afore mentioned problems which could eventually be caused
by transfer resistances in the cable and EMC can be prevented
by installing a 2-wire transmitter (output signal 4 ... 20 mAl in the
sensor head. Required is only a 2-core copper cable. Multiple
wire circuits for resistance thermometers and compensation ca
bles for thermocouples are not necessary.
When using the transmitter, please take notice of the following:

the contents of these instructions or the operating manual
provided with the transmitter
the relevant rules involving the installation and operation of
electrical systems, in some cases the regulations and direc
tives for explosion protection.
5. Mounting and Operation

5.1 Installation
The thermometer (thermocouple, resistance thermometer) must

be brought into contact with the medium to be measured in the
best possible manner.
To avoid thermal conduction errol's, the immersion depth should

be:
in fluids 6 ... 8 times greater
in gases 10 ... 15 times greater
than the protective tube diameter. If only very short insertion
lengths are possible, special designs should be applied. It is of
ten helpful to install in a pipe bend, whereby the protective tube
must be positioned against the flow of the medium,
5.2 Connecting wires
For all connecting wires it is important to ensure that proper con If possible, all measuirng systems should be operated in un
tact has been established and that corrosion, humidity, pollution, grounded condition, or only grounded at one point.
electrical parasitic interferences of power cables etc. are avoided.
When using thermocouples connected to protective tubes, these

The cables should be insulated to counter the ambient influences should be the only ground/mass connection.
(dry, humid, chemically aggressive, hot), whereby the ambient
temperature of both the cable and the connection head may not
exceed 100 cC.
Please pay attention to the valid standards and regulations when
selecting the types of cables to be used.
3
5.3 Instructions for explosion prooved Components
1. In accordance with of ElexV, rlaintenanCfJ work (repairs) 4. When ordering spare parts, exacl information on previous
may be conducted only und['I' the following conditions delivery such as type of protection (Exd, Exi), No. of the
stated below' certificate of conformity. serial and item No.s must be
supplied.
1.1 If a part of an eleclflcal devicE willch IS important for ex
plosion protection is repaired, this may be put into opera
5. Ex'protected thermometers only fulfi' the required safety
lion only after a technical expert has determined that the
lequlrements as a unit component, as detenTllned by the
main explosion protection characteristics still correspond
cerlficale of conformity. Measurirlg Insets or connecting
to the required standard and after issuing a certificate or
heads alone do not satisfy :he explosion-protection re
awarding a test mark.
quirements.
1.2. Item 1.1 shall not be valid if the compon(';llt has been in
diVidually tested by the manufaclurel' and It IS confirmed 6. If SENSYCON supplies thermometers destined for opera
that tile main characteristics fOl' application in hazardous tion in hazardous areas without protecting tubes. it will be
areas comply With the stipulated technical requirements. the responsibility of the owner to see to it that
6.1. these thermometers are deployed only in zones which
2. The ElexV is only valid withi!1 the Federal Republic of
are permissible In accordance with lhe certificate of COI1
Germany. in foreign countries, the relevant binding regu
forrTllty or with lhe manufacturer's declaration (e.g. zones
lation corresponding to ElexV must be adhered to.
1 01' 2)
3 Repair work may only be carried out uSing original com 6.2. a protecting tube is pmvlded for all eventually necessary
ponents of the original manufaclurer', olherwise the stan separation of a ZOlle (e.g. zone 0 from zone 1). Such a
dards slipulated in the certificate of conformity shall not tube must correspond fully to the 'speCial conditions"
be fulfilled spelled oul In the respective certficate of conformity.
7 SENSYCON shall inform the plant owner of the above

subject matter in appropriate form, e.g by drawing atten
tion to this leaflet of instructions.
5.4. Protection Tubes
Thermometers can be installed in any mounting position. prefer If they are applied to hot processes (e.g. when changing the
ably hanging vertically, up to temperatures reaching about thermocouple), they must be either prewarmed or Illserted very
500°C. slowly (1...2 cm/min at 1600 ac, 10.. .20 cm/min at 1200 DC). This
also applies when removing the hot protecting tube. Care must
Ceramic protection tubes must be protected from mechanical
be taken to avoid suspending lengths> 500 mm for temperatures
stress (bumps, bends), including temperature shocks e.g.
> 1200 DC.
through direct flame contact.
6. Maintenance
The thermometer and the entire temperature measuring circuit
In both cases, substantial deviations from the set point can be
must be checked at regular intervals for
determined, also if the thermometer or the instrumentation is the
- wear and tear of protecting tube or chemical activity.
cause of function errors.
- drifts of the measuring element caused by ageing,
The insulation resistance of the entire ungrounded measuring

reduction of insulation resistance through humidity and
circuit (wires and thermometer) against ground should be > 1 MQ
pollution
(measured with 100 V DC).
improper contact of the wire connections and
mechanical and chemical damage of the thermometer and
wires.
Resistance thermocouple circuits can be checked by replacing

the measuring element with a known defined resistance, thereby
simulating a specific temperature.
Thermoelement measuring circuits can be checked by connec
ting a mV voltage of a known variable to the measuring circuit,
instead of the thermocouple.
4
7. Troubleshooting
7.1 Quick Check
of thermocouples and resistance thermometers, including their A heating up of the thermocouples or resistance thermometers
associated measuring circuits in dismantled form. to between 200 and 400 cC (without temperature control) gives
further clues to interruptions, polarity errors (for thermocouples),
Required instruments: mV-meter, Q-meter or resistance bridge, and low insulation resistance etc.
insulation meter with 60 ... 100 V voltage (all measurements at
The accuracy of thermometers according to ISO 9000 can only
room temperature)
be checked by a reference element.
In the case of room temperature the throughput and insulation Therefore in most cases the thermometers has to be removed
are checked by "knocking" to see if any wire breaks have oc and checked by a heating device.
curred.
A thermocouple is regarded as being in order if R < 20 r2 (wire
> 0.5 mm diameter); the value depends on the wire cross-section
and the length. R"ol 100 mn (for insulated thermocouples).
A resistance thermometer is considered to be in order if R is
about 100 n (for Pt100), R"ol > 100 MQ.
7.2 Error Table for Thermocouples and Resistance Thermometers
The entire temperature measuring circuit should be routinely

checked.
The following tables contain an illustration of the most important
errors and provide suggestions towards their solution.
fault probable cause remedy
errors in the measuring signal electrical/magnetic pick-up - at least 0.5 m spacing between the
measuring cable and power cables
supply lines if laid in parallel
- electrostatic shielding caused by a
metal foil/braiding grounded at one
point
- twist the core wires (in pairs) to
combat magnetic pick-up
- right-angled crossing of electrode
with interfering power cables
grounded loops - only one grounding point in circuit or

"floating" measuring system (un
grounded)
drop in insulation resistance - humidity has eventually penetrated

the thermometer/inset; in such case
dry up and reseal
- replace inset
- check to see if thermometer is ther
mally overloaded
5
response times too long, inco!Tect wrong location for installation; there is a - change the point of Installation so
readouts heat source within the flow path that the medium can transmit its
temperature to the thermometer
without interfel'ellce
,
wrong installation: - immerSion depth approximately tem

- Insufficient installation depth perature sensitive length + 6 "
- excessive loss of warmth (fluids) up to 10 x (gases) d (d =
external protecting tube diameter)
- ensure that thermal contacts, espe
ciaily for surface measurements are
established with matching contact
surfaces and/or heat conducting ma
terials
protecting tube too thick, drilled Ilole for - select the smallest possible protec
protecting tube too bi~l ting lube for the process: response
time at first exposure should be pro
portional to the cross-section or the
volume of the thennometer, depen
ding on the tentative thermal figures
and air gaps within the assembly,
Fill any such gaps with contact
agent (oil, grease) if possible,
deposits on the protecting tube - remove during inspections

- if possible, select another protecting
tube, another installation point
thermometer interruptions vibrations - reenforced springs on inset

- shorten inset insertion length
- change the measuring point (if pos
sible)
- special construction of Inset and pro
tecting tube
highly corroded protecting tube - composition of the medium is not as ,- check the medium, eventually ana
assumed, or has changed Iyze the defective protecting tube
- unsuitable material chosen for pro- and select a more suitable material,
tecting tube whilst providing additional surface
protection
- in certain circumstances the protec
ting tube must be replaced from time
to time, since it is subject to wear
-
Typical Thermocouple Faults
fluctuating temperature readout even reference junction temperature or vol-, - temperature or supply voltage must
though thermocouple circuit is faultless tage is not constant be kept constant at < 0,1 %; check
instruments
- for non-precious metal-thermocou
ples use the full value for measure
ment; use only about half the value
of thermocouples made of precious
metals
- --
temperature display highly deviates improper malerial combinations, check thermocouples arid wires for
from the table values for bad electrical contacts, - correct pairing
thermocouples parasitic voltages (thermostatic - correct compensation lead
voltages, galvanic voltage), - correct pinup

wrong compensation cable - permitted ambient temperature at
connection head
6
Typical Resistance Thermometer Faults
,---- -----
too high or fluctuating temperature - wire resistance too high. uncom if still possible.
readout despite known cross-section, pen sated - select 2-wire leads with bigger
accurate sensor of the resistance ther- - supply lead resistance altered by cross-sections eventually move to a
mometer high temperature more acceSSible point
- shorten wire
- lead adjustment
- change to 3 or 4 wire system
- use the head transmitter
fluctuating temperature readout even voltage or power supply is not constant Must be kept constant at < 0.1 %. Fully
though measuring circuit of the resis affects the measurement when tuned
tance thermometer off bridge and current/voltage measure
ments (4-wire).
----"-
8. Wiring diagram and color coding

r-----------------------------------
Pt100 2 x Pt 100
2-wire system 3-wire system 4-wire system 2-wire system
____ red
,-'-~ red ~red
red 00--------,--- --e red t~red
white
~
epY • black
white ., white t.=-~ white
• white
_. __.• yellow
red
red
red yellow red
single thermocouple double thermocouple
Fig. 1 upper ha'f: resistance thcl'ITlonleier according to DIN EN GO 751

Z-18845 lower half therrnocouple according to DIN EN 60584
7
Our Information regarding our products, equipment, plants and processes is based on extensive research and experience in the
field of applied engineering. We are making such information available. to the best of our knowledge and in Wrlttell form, without
assuming any liabilty over and above the terms of this contract but reserving the right to make technical changes of our products
at any time without prior notification. In addition, our aplications engineers are available on request to provide further consultation
and cooperation ifl solving production and application-related problems.
This however does not relieve the user from the obligation to verify the suitability of our information and recommendations before
putting our products to use.
This applies particularly to deliveries destined for customers in foreign countries, especially in their obligation to ensure that no
patent rights of third parties are infringed upon, including applications and processing methods which we have not expressly
spelled out in writing. In case of damage or quality deficiencies, our liabilities and indemnities are limited to the same volumes as
stipulated in our General Terms of Supply and Delivery.
Subject to technical changes.
This technical documentation is protected by copyright. Translating, photocopying and diseminating it in any form whatsoever - even
editings or excerpts thereof - especially as reprint, photomechanical or electronic reproduction or storage on data processing systems or
networks is not allowed without the permission of the copyright owner and non-compliance will lead to both civil and criminal prosecution.
Jlll II
,.'1.1. ---------- -----------
Subl8Ct to iechnical changes.

ABS Automation Products GmbH Prillted In tne Fed. Rep, of Germany
Borsigstrasse 2 42/10-20 EN Rev, 2,0
D-63755 Alzenalj Edition 03.01
Phone +49(0)60 23 92 . 0
Fax +49(0)60 23 92 - 33 00
http://www.abb.com
VOITH
14.2 Pressure gauge with shutoff valve
14.2.1 Pressure gauge
Type: 100 T5500 S WL 15 L
Measuring range: 0-6 bar
Degree of protection: IP 65
Glycerin-filled
Data sheet ........ G1.T5500 / D
Operating instructions ......... , , , . ' , , .. , . ' , ' ........ GAUGE - BA
14.2.2 Shutoff valve with test connection
Type: 2-valve manifold
Drawing ........... , ................................ 42015280
14.2.3 Primary shutoff valve
Drawing ........... , , , , ............................. 42240940
m
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128
®
~ASHCROFT
All stainless steel process gauge open or solid front
Model T5500 and T6500
According EN 837-1
Nominal size 100 mm or 160 mill
Accuracy Class 1 (DIN)
Features
.. Rugged stainless steel construction
to Socket and case welded
• Protection IP54 and I P65
.. Usable to full scale
II Overload protection 130 %
.. Dry, liquid filled or liquid less (PLUSI gauge)
• Measuring system stainless steel or Monel
II Optional contacts
Ranges
-1 ... 0 bar up to 0 ... 2500 bar
-30 in. Hg ... 0 psi up to 0 .. 36.000 psi
Applications
Chemical and petrochemical industry
Machine and apparatus construction
Food and beverage industry
Pulp and paper industry
Technical specification T5500 T6500

...~.
Dial size [mml 100 160 100 160
Construction Open front cylindrical case With blowout disc at the Solid front safety pattern cylindrical case with blow
back out at the back
Measuring principle irdon tube
Range [bar] 0,6 1 1,6 2,5 4 6 10 16 25 40 60 100 160 250 400 600 1000
1600 2500 -110 -1/0,6 -1/1,5 -1/3 -1/5 -1/9
Overpressure limit 130 % F.S., short time
Pressure type Gauge, vacuum and compound
Process connection G Y. B male, G Y, B male, G 3/8 B male according EN 837, M20x1,5 male,
R Y, male tapered (DIN 2999), y," male straight (,liS, BSP), 3/8" male straight (JIS, BSP)
Y. NPT male, Y, NPT male according ANSIIASME Bl.20.1
9/16-18 UNF-2B Aminco (high pressure),
Others on request (for pressure limitations see order information)
Connection location Lower, back Lower only
Material
Pressure connection Stainless steel 316L (1.4404), optional Monel

Tube Stainless steel 316L (1.4404), optional Monel, > 1000 bar Ni Span
Caselbayonet ri ng
Window
Stainless steel 304 (1.4301), optional 316L (1.4404)
Instrument glass, optional laminated safety glass or
acrylic glass
I
Laminated safety glass, optional acrylic glass
Dial Aluminum, black markings on white background
Pointer Aluminum, black, optional micrometer adjustment, red set hand or maximum pointer
Movement Stainless steel 304/303 (1.4301/1.4305)
Accuracy Class 1 (1 % F.S.), optional 0,5 % F.S.

Permissible
Ambient temperature -25. .60 'C
Medium temperature max. 100 "C
Storage temperature -40 ... 60 "C
Effect max, 0,3 % 1 10K
Protection according EN 60 52911EC 529 IP54 (dry), IP65 (liquid filled), optionallP65 for dry gauges
Filling liquids Glycerin, silicone, halocarbon, others on request
Optional dampened movement (liquid less gauge), functions as liquid filled gauge (PLUSI gauge)
Mounting Standard stem, optional flush or surface, others on request
Weight drylfilled [kg] 0,8/1,0 I 1,2/2,0 0,8/1,0 I 1,2/2,0
Accessories, options Diaphragm seals, valves, gauges with contacts (see Gl.K55/E), gauges with electrical output. NACE
All specifications are subject to change without notice,

G1.T5500/E Rev, K 03/03/2004 Instruments
~ASHCROFT®
General dimensions [mm]
[
L2
I ~
N
ro
:qr
d. 1__'
D'sw
L 01. J
T6"00
Order information
Size Type System Execution Process Connection Range Engineer- FiliinglCase ma- Options
material connection orientation inq units terial
(100) T5500 (5) 316L (0) IP54 (04) y, NPT(L) Lower

male 1)
-1/0 " (BAR) (=) Standard (NH) Tagging wired
100 mm (1.4404) -11 1,5 no filling
(OA) Dial Marking
s: 1000 bar (Ll Liquid (B) 8ack 1) -1/ 3
(160) T6500 filled (02) y,. NPT -11 5 (GV) Silicone (TU) Throttle plug stainless
160 mm (P) Monel 400 IPr,5 male 1) -11 9 steel
s: 1000 bar (GV3) Silicone
(6B) cleaned
(09) 9/16-18 01 0,6 2,
3 cst (ooell front) ace
(M)MoneI400 UNF-2B 01 1 837-1)
tube, Aminco 01 1,6 (GR) Glycerin 1)
(MP) Micrometer pointer
316L 01 2,5
(1.4404) (13) G y,. B male 01 4 (GX) Halocar- (PO) Acrylic glass
1) bon 2)
socket 01 6
(SG) Safety glass
s: 1000 bar 01 10
(14) G 3/8 B 01 16 (YW) Case ma- (FX) Front flange
(0) r-..ii span male 1) 01 25 terial 310L
(FW) Back flange
tube, 01 40 (1.4404)
316L (15) G Y, B male 01 60 (8Q) Wall mounting bracket
1)
(1.4404 ) 01 100 ( ) Contact 16500)
socket 01 160 type and (UF)
> 1000 b31' (16) M20x1,5 01 250 function
male 1) 01 400 (see
Field fiIIable
01 600 G1.K55/E) (LJ)
(only for exec!"-"tlcn D IPelS)
(KQ) RY, male 0/1000
tapered 0/1600 (AJ) Calibration 0,5 % F.S,
DIN 2999 (not for range 010 bar fi'led)
1) 0/2500
(ll) Liquid less gauges
(KN) /," male (Halocarbon fliling not allowed
straight 1) not allowed
(NS) Liquid less gauges,
(JIS,BSP)': with
1) silicon free
not for ran;)2S ;O~ execution L)
Opt.ICi~l
(KP) 3/8" male '.2.5 bar
no! ,'P.J
straight (PR) Receiver gauge
-"vith 2)
(JIS,BSP)') \:on L or not allowed 'I
1)
combinatic)l'
1)
fo ; psi and other liquid less ("-Li
max. 1000 bar TG500 ol'IIC)", on reauest option
How to order
Size Type bystem Execution Process Connection Ra'lge Engineering fllllnglCase Opt:Ofl
material connection orientation unit material
100 I I T5500 I I s o I 15 I L 0/16 I BAR I YW NH
DRESSER EUROPE GmbH Instruments Website: www.dresserbae.de e-Mail: sales@dresserbae.de

Gennany France United Kingdom
Max-Planck-Str. 1, D-52499 Baesweiler ,206' ZA Le Mandlnet Rue des Campanules East Gillibrands
PO. Box 11 20, D-52490 Baesweiler F-77185 Lognes Skelmersdale. Lancashire WN8 9TU
TeL: +49 (0) 24 018080, Fax: +49 (0) 24 01 808125 TeL: +33 (0) 1 60372530 Fax: +33 (0) 1 60 372539 TeL: +44 (0) 16 95 52 G90 Fax: +44 (0) 169552693
a
- Si 18 temperature du process au niveau du mano est superieure la temperature 6. Reglage du zero
~A5HCROFT®
maximum admissible, alors II sera necessaire de monter un siphon, un separateur Pour les instrument a lunette amovible au munls dune systeme de remise a zero
ou un capillaire suffis8mme!1t long. Utilisez tOUjOLFS clefs adaptees au plats du externe, Ie zero peut etre. Pour les instruments munis dun systeme de reglage
mana. Ne jamals appliquer de forces sur Ie boitier. a
interne du zero, la lunette baionnette ou articulee peut etre aisement enlevee,
3. Mise en service pour les manometres lunette visee, VOir Ie schema pour retlrer la lunette. Betriebsanleitu ng
a a
- L'echelle d'operation correspond la pleine echelle sinon se referer la marque 1. Tenir la manometre solidement fixe. il est important de Ie tenir etroitement
"f" indiquant la limite de pression. Pour les mana's differentiels, venfier la pression sinon les ergots de la lunette pourraient etre endommages.
Druck- und Differenzdruckmanometer
statique maxi. Pendant les essais d'elancheite des tuyaux, les mana's ne doivent 2, Pour retirer la lunette, tapoter dans Ie sens inverse des aiguilles d'une montre
pas eire exposes hors limites indiquees, La temperature d'etalonnage est de comme IIldique en utilisant un marteau et un tournevis a bout plat.
+20 "C. chaque deviation de +30 °C ajoute ± une classe de 18 valeur pleine a
3. Pour Installer la lunette, la serrer land a la rnalil. Tourner comme indlque sur
a
echelle la precision. Les tuyaux vers les manos dOlvent avoir un diametre In Ie schema d'l/S de tour pour I'etancheite at d'1/3 de tour pour les boltiers a Operating Instruction
terne entre 4 et 9 mm, en fonction de la pression et de la longueur. bain au hermehque.
- Apres I'installation de mana's differentiels, les lignes de mesure doivent etre Les manometres differentiels ont un ajustement externe sur Ie cote du boitier. Pressure- and DP gauge
ventilees (purgees pour liquides). a
Les manometres etalons lunette amovible sont equipes d'une vis de remise a
- Jusqu'a la mise en service d8finitive, la vanne d'isolement doit rester fermee et la zero sur la fayade (voir schema 2).
vanne d'equilibrage ouverte. Faire attention aux charges unidirechonnels, 1. Desserrer la bague de verrouillage "A'
- Au demarrage pour les mana's ouvnr la vanne d'isolement lentemen!. 2. Faire tourner Ie bouton ,,8" pour ajuster Ie zero. Instruction de Service
Pour les mana's differentlels, sUlvre les instructions suivantes pour: 3. Serrer la VIS "A' sur Ie bouton ,,8',
- Mise en service: 1. Ouvnr la va nne d'equilibrage L'aiguille ne pellt eire remise a zero qu'apres avoir Ilbere I'element senSible de
Manometre et Manometre differentiel
2. Ouvm les vannes d'isoler'1ent tout pression.
3. Fermer la vanne d'equilibrage Sous reserve d2 modificatioilS I
La pression differentielle est Indlquees sur Ie cadren
Mise hors service 1. Ouvrir la vanne d'equillbrage
2. Fermer les vannes d'isolemen!.

Dresser Europe GmbH
Service en zone dangereuse (model T55001T5500):
Bild I sketch I schema Niederlassung Baesweiler
Ambiance -20. 50°C 1 2
Le "Process": Les temperatures maxi des fluides, gaz et vapeurs en contact avec
I'instrurnent dependent de la construction de I'appareil alnsi que la GermanylDeutschland/Aliemagne
temperature d'lnflammation des gaz, vapeurs ou poussieres dans Max - Planck - Straf!,e 1
I'ambiance (VOir tableau 1):

Attention: Pour les gaz, la temperature peut 8ugmenter a cause de 18 com o - 52499 Baesweiler
pression; ceci limite la frequence maxi admiSSible (pas les pulsa 0) +49 (0) 24 01 80 80
tions) jusqu'a 0,1 Hz. Ce n'est pas applicable pour les manometres
remplls d'un bain d'huile amortisseur. Fax: +49 (0) 24 01 80 81 25
Tableau 1 Temperature du "process" maxi.

Classe de tem erature Temperature du "process" maxi
T6 +55°C
England/Angleterre
T5 +70°C Tabelle ! table / tableau 2 East Gillibrands
T4 +100°C Skelmersdale, Lancashire WN8 9TU
T3 +100°C max. Umgcliungstcmperatur I ambient tE'mperature limits! temperature ambiante maximum

T2 +100"C Ausfuhrung
"C OF CD +44 (0) 16 95 52 600
T1 +100°C execution
Pendant les essals de chocs Ie degre de risque mecanique a ete classifie comme type de boitier
Fax: +44 (0) 169552693
leger. hermetisch dicht
hermetically sealed
Luft I air! air - 25 ... 50 - 10 ... 125
4. Zero au test de fonctionnement France/Frankreich
- La vanne d'isolement du mano fermee, la pression do it etre amenee a 18 pression herrnetique
atmospherique. L'aiguille dOlt rester a zero, FllissigkeltsgefLJllt
Glycerin / glycerin J glycenne I- 18 ... 65 0 15C

,,206" ZA Le Mandinet Rue des Campanules
- Verification pour les mano's dlfferentiels. Ferrner I'ensemble des vannes a la prise liquid filled
F-77185 Lognes
de pression en meme temps. L'aiguille do it reste dans lechelle. Si I'aiguille des a bain
Silikon J Silicon / silicone - 45 ... 65 - 50 .. 150
cend, la partie haute pression a des fuites ou la va nne d'equilibrage est restee FOliflussigkeii unu Messstoff mussen kompatibel sern.
+33 (0) 1 60 37 25 30
ouverte. En cas mantee de I'aiguilie, la partie basse pression a des fuites. Si Ie Be sure filling liquid is compatible with process fluid
Fax: +33 (0) 1 60 37 25 39
mana ne mantre aucune indication, fermer la cote basse pression et ouvrir la S'assurer Que Ie liquide de remplissage est compatible avec Ie fluide de service.
haute pression. Si I'aiguille ne bouge pas. I'instrument est defectueux.

5. Maintenance
- L'lnstrument ne demande pas une maintenance particuliine.
GAUGE-BA Rev, K 09/04/2004
- En cas de delaut, demander I'assistance de nos agents ou la notre. Nous vous
apporterons conseil et service.
fnstruments
1. Montagebedingungen !g undlcht. Zelgt das Differenzdruckmessgerat nichts an, Minusleitung - Service in hazardous area (model T5500/T6500)
- Die Manometer mOssen nach den In Betracht kornmenden Anforderungen ausge und Plusleitung offnen. Bewegt slch der Zeiger nicht, so ist das Gemt dc, Ambiance -20 .. , 60 °C
wahlt und montiert werden. 5, Wartung Process media' The admissible temperature of the process media depends on the
- Zulassige Umgebungstemperatur siehe Tabelle 2. Andere Temperaturgrenzen sind - Das Gerat ist wartungsfrei. instrument constructron as well as the ignition temperature of the
optional mit speziellen Serien moglich. - Lassen sich St6rungen nicht beheben, wenden Sie sich bilte an unsere Niederlas surrounding gases, vapors or dusts (see table 1)'
2. Montage sungen und Vertretungen, die Ihnen mit Beratung und Service zur Verfijgung Attention: For gaseous media the temperature can rise as result of compres
- Der Einbau des Messgerates sollte in der Niihe des Messpunktes erfolgen. Der stehen. sion. Therefore the maximum admissible frequency (not pulsation)
Einbauort sollte zuganglich und frei von Erschutterungen sein. 6. Nullpunktkorrek!ur is 0,1 Hz. This does nol apply to liquid filled gauges
- Die Betriebsstellung muss mit der auf dem Zifferblatt angegebenen Gebrauchs Bei Messgeraten mit abnehmbaren Frontring oder externer Verstellmbglichkeit Table 1: Maximum admissible process media temperature
stellung Obereinstimmen. Ohne Angabe auf dem Zifferblatt ist die Gebrauchslage kann der Nullpunkt einges!ellt werden, Temperature class Max, rocess media temperature
90 +5 (Zifferblatl in vertikaler Lage).
0 0 Bei Messgeraten mit interner Nullpunktverstellung muss der BaJonett-Ring bzw, ~ ~5~
- Bel extremen Bedingungen (Druckspilzen, Vibrationen) Schulzelemente verwen der klappbare Ring vorsichtig entfernt werden. Messgerate mit geschraubtem T5 +70°C
den (Dampfungselemente, Fullflusslgkelten). Ring werden wle In Gild 1 dargestellt gebffnet. T4 +10Q"C
- Das Messgerat ist vor schadlichen UmwelteinflLJssen, Beschadigungen, grol1en Ger"t (3) mit elner Schulzhulse (2) im Schraubstock einspannen. T3 +100"C
Temperaturschwankungen und, bel Dlfferenzdruckmessgeraten, vor einseitiger 2 Schraubnng vorslchtig mit einem Hammer und einem grol1en Schraubendreher T2 +100"C
Warmestrahlung zu schulzen, (1) gegen den Uhrzeigersinn losen. T1 +100 ~
- Differenzdruckmessgerate mussen frostSlCtler elngebaut werden, 3. Nach der Nulipunktkorrektur Schraub[lcg von Hand fest andrehen, Bei wetter During choc tests the degree of mechanical hazard was claSSified as low.
- Jberschreitet die Temperatur des Messstoffes die zulassige Betriebstemperatur, fester ?,LJsfuhrung eine 1/8 Umdrehung bel hermetisch dichter und gefUllter 4. Zero or functional test
so muss eine ausreichend lange Messleltung, eln Wassersackrohr oder ein Ausfuhrung elne 1/3 Umdrehung nachzlehen. - The shut off valve(s) at the pressure tap(s) for the instrument has to be closed
Druckmittler mit Kapillarrohr vorgeschaltet werden. Oifferenzdruckmessgerate haben eine 8xterne Verstelimoglichkeit an der
and the pressure has to be released to atmosphere. The pointer tip must stay
Beim Montieren ist ein entsprechender Mauischlllssel zu verwenden, Es darf keine Genauseseite,
within the zero mark.
Kraft (Moment) auf das Gehiiuse ausgeiJbt werden. Feinmessgerate mit klappbarem Ring haben eine frontseitige Nullpunktkorrektur
- Check for dp gauges: Close both valves at the pressure taps at the same time.
3, Inbetriebnahme (siehe Bild 2).
The pointer must rest Within the scale range, If pointer drops the plus line leaks or
- 1st auf dem Zifferblatt kelne Begrenzungsmarke " aufgedruckt, so ist der Verwen 1, Feststellschraube A losen.
the balancing valve is still open. In case of rising pointer the minus line leaks, If
dungsbereich gleich dem Anzeigebereich. Bei Differenzdruckmessgeraten 1st der 2, Mit der Justierschraube B den Nullpunkt einslellen.
the dp gauge shows no indication, close the minus line and open the plus line. In
maximale statische Druck zu berucksichtigen. 3. Feststellschraube A III Justierschraube B eindrehen, case the pointer doesn't move the instrument is damaged,
- Beim Abdrucken von Rohrleitungen und Kesseln darf das Messgeriit nicht hoher - Vor der Nullpunktkorrektur ist ein Druckausgleich erforderlich. 5, Maintenance
als die vorgenannten Begrenzungen belastet werden. Technische Anderungen vorbehalten l - The instrument requlfe no special maintenance.
- Die Bezugslemperatur betragt +20 °C (Normaltemperatur bei betrieblicher - In case of any default apply for assistance from ourselves or our agents. We will
Eichung). Abweichend von der Bezugstemperatur ergibl sich je 130°C Betnebs assist you with advice and service.
1. Installation requirements
temperalurzunahme bzw. Abnahme ein zusatzlicher Anzelgefehler von ±1 % 6. Zero adjustment
- The pressure gauges must be selected and installed this wise, that the possibility
bezogen auf den M. E.. For instruments with a removable ring, bezel or external zero adjust feature the
of failure, resulting In injury or misapplication, IS minimized. zero can be adjusted, For the instruments With internal zero adjustments the
Die Anschlussleitung sollte, in Abhanglgkelt von Druck und Lange, einen Innen
For the maximum ambient temperature see table 2. Other limits are possible at bayonet ling or hinged ring bezel must be removed, for gauges with screwed ring
durchmesser von 4 ... 9 mm haben.
special series
- Nach der Montage eines Differenzdruckmessgerates sind die Anschlussleitungen see sketch 1 to remove the ring,
2. Mounting riold gauge in vise with threaded nut. it is Important to hold the gauge rigidly
auszublasen, bzw. bei flOssigen Medien zu entluften. S'S zum Einsatz bleibt das
- The mounting of measuring instruments shall be in proximity of measuring pOint,
Anschlussventil geschlossen und das Allsglelchsventll geoffnet. Einseitige Druck othecNise ring lugs may be damaged.
easily accessible and safe from vibrations and always coincide with the position 2 To remove ring-tap counter wise as shown USlllg hammer and large screw
belastungen sind zu vermeiden
as Indicated on the dial. If no such statement is printed on the dial, the gauges
,Absperrventile immer langsam offner:. driver with flat tip
must be mounted in a 90° ±5° position With the vertical dial. If the instrument can To install ring lighten snugly by hand. Turn as per sketch 1/8 turn for weather
Bei Inbetriebnahme von Differenzdruckmessgeraten wie folgt vorgehen:
not protected against shock or vibration, use an additional movement damping proof and 1/3 turn for liquid filled and hermetically sealed
1 Ausgleichsventiloffnen 2. Anschlussventil otfnen.
feature (liqUid filled or pulsation dampener), The measuring instrument must be The differential pressure gauges have an external adjustment on the side of the
3, Ausgleichsventll schliellen. Der Differenzdruck wird angezeigt.
protect against damages, great pollution, high fluctuation of temperature and one case.
Bel Aul1erbetriebnahme wie folgt vorgehen:
sided heat radiation for the dp gauge, Please note the freezing point of media and - Testgauges with hinged ring are equipped with a front mounted zero adjustment
1, Ausgleichsventil offnen, 2. Anschlussventil schlier:len.
choose a frost-protected place for the dp gauges. (see sketch 2),
Ernsatz in explosionsfahiger Atmosphare (Modell T55001T6500)
- If the process temperature at the gauge is in excess of the max. allowable opera 1. Loosen ring locking screw A.
Umgebung: -20 60 "C

tion temperature, than depending of the application a syphon, diaphragm seal or 2 Rotated knob B until required adjustment.
Messstoft- Die zulassige Messstofftemperatur hangt aul1er von der Geratebau

sufficient length of pipe/capillary has to be mounted between the pressure tap and 3 Tighten screw A down on knob B.
art auch von der Zundtemperatur der umgebenden Gas, Dampfe

the instrument The pointer can be adjusted to zero after releasing the pressure element against
bzw. Staube ab (siehe Tabelle 1):

- When installing always use a wrench suitable for the flats on the instrument. Do atmosphere.
Achtung Bei gasf6rmigen Stoffen kann sich die Temperatur dureh Kompres
never apply mechanical torque's 10 the case, ~dification reserved 1
sionswarme erhohen Auf Grund dessen darf die Frequenz von 0,1
3. Operation
Hz (nicht Pulsation) nlcht uberschritlen werden. Dies trifff nicht bei
The operating range corresponds to the scale range or see static pressure Ilm!t
gefUliten Geraten zu.
mark T printed on the dial. For dp gauges look for the max, allowable static pres
Tabelle 1: Zulassige Messstofftemperaturen Conditions de montage
sure. When carrying out pressure test of process pipes and vessels, the instru
Temperaturklasse I Max. Messstofftemperatur
ment may not exposed to the above limits as mentioned before, The calibration
a
Les manometres doivent etre choisis et montes de rnanler~ minimiser les
T6 t +55°C
temperature IS +20 "C, each ±30 °C deviation of this temperature adds ± one
possibilites d'erreurs, resultant d'un mauvais montage d'ulle mauvaise applica
T5 I +70°C
class of full scale value to the accuracy.
tIon.
+100°C - Pour la temperature ambiante maximum, se referer au tableau 2. D'autres limites
T4 I ihe instruments piping shall be between 4 and 9 mm 10, depending on the pres
sont possibles dans des modeles particullers.
T3 +100°C
sure and the lengths.
T2 I +100°C 2. Montage
- A.fter installation of the dp gauges the measunng lines must be blowed through
T1 I +100 °C
When using liquid media, the measuring lines must be bled,
a
- Le montage de mano's doi! etre fait proXlmlte du pOint de mesure, facilemen!
Bel der Stor:lpru(ung wurde der Grad der mechanischen Gefahr als niedrig ange accessible, exempt de vibrations et toujours co'lncider avec la position indiquee
- Until definitive operation the connection valve remains closed and the compensa
sehen. sur cadran, En standard, les manometres doivant etre montes a 90°15" par rap
tion valve remains open. Please avoid one-sided charge,
4, Nulipunktprufung/Funktionstest port au cad ran a la verticale. Proteger les mana's contre les chocs au les vibra
- On start up for pressure gauges open the shut off valve slowly.
- Nach dem Schllel1en der Absperrventile und erfolgtem Druckausgleich muss der tions ou utiliser un systeme d'amortrssement supplementaire (remplissage ou
- For dp gauges follow the follOWing sequence for:
Zeiger im, als Nullpunkt, gekennzeichneten Bereich stehen. amortisseur), Le mano doit etre protege contre avaries, pollution, hautes fluctua
- Operation: 1. Open balancing valve, 2. Open connection valves.
- Bei Differenzdruckmessgeraten steht der Zeiger bei gleichzeitigem Schlierlen der tions de temperature et chaleur d'un cote de I'appareil pour Ie mano differentiel.
3, Close balanCing valve,
Ventile Innerhalb des Anzelgebereiches. Fallt der Zeiger, ist die Plusleitung un Noter la point de gel du fluide et choisir une place protegee du gel pour les ma
Differential pressure is indicated on dial
dicht oder das Ausgleichsventil nicht geschlossen. Steigt der Zeiger, is! die Mlnus no's differentiels.
- Out of operation: 1. Open balancing valve. 2. Close connection valves
iJ;I*i9#i~ INSTRUMENT I
CE EUROPEAN OPERATIONS
A Haliburton Company
Konformitatserklarung Declaration of Conformity

EG - Richtlinien EC direction
DRESSSER EUROPE SA
Max-Planck-StraBe 1
0-52499 Baesweiler
Wfrerkijren hiermit in alieiniger Verantw()rtung, -- FWe hereby declare under-soleresponslbility tha(-

da!3. die folgenden Produkte in Obereinstimmung following products are in conformity with the
mit den Bestimmungen der benannten EG- ' provisions of the following EC-directives and the
Richtlinien sind und die aufgefUhrten Normen und 'listed standards and technical specifications have
technischen Spezifikationen zur Anwendung been applied
!-'gL:'ec.:..:1ac.,:n.:. s;1Ql-'-'t--=.s""'in-'.:d_____________ ---------'------------------------------
Bezeichnung : Schalter (Temperatur-, (Differenz-)Druck-)

Specification: Switch (temperature-, (differntial-) pressure-)
Typ I Artikel-Nr. / Baureihe : B-.., D-., L-.. , G- .. , P-.. , T- ..

Type I Part-No. I Series:
Serien-Nr Ab lieferdatum 01.01.1997

Serial No : Supplied from 01.01.1997
Spezifikation :
Specification:
EG-Richtlinie : 73/23 I f3NG Niederspannungsrichtlinie

EC-directive : Low-Voltage Directive
,A,ngewandte Normen : EN 60010-1 Sicherheitsbestimmungen MSR

Applied standards: EN 60947-7 Niederspannungs-Schaltgerate
EN 60 947-7 Niederspa nnu ng-Sch aItgerate
kombinationen
Herstelier-Unterschrift . Tom Fiedler

Signature of manufacturer:
Funktion des Unterzeichners : Engineering

Function of signer:
Datum: 16.011997
Date: DRESSER EUROPE S.A.
Stempel
INSTRUMENT DIVISION
Stamp Max-Planck-StraBe 1
0-52499 Baesweiler
Postfach/P.O. Box 11 20
D-52490 Baesweiler
Tel. 02401 180 SO· Fax 0 24 01 • 70 ~7
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VOITH
14.3 Pressure switch with shutoff valve
14.3.1 Pressu re switch
Type: 44 V1-AA45-M4-C1 A
Range of adjustment 0.3 - 5.2 bar
Description ...... , , ... , , ..... , , ....... , ..... , ............ SOR
14.3.2 Shutoff valve with test connection
Type: 2-valve manifold
Drawing ........... , ................................ 42015280
Drawing ...................... , ................... , .42240940
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129
Dual Hi-Lo
Pressure Switches
General Instructions
V1
Weathertight Process Connection
Housing
Securely connect the process line to the pressure port using
two wrenches; one to hold the hexagonal flats on the pressure
port, the other to tighten the process pipe or tube fitting.
IMPORTANT: Ensure that the process connection is

tightened and positioned so that bending and torsional forces
V2 imposed on the pressure switch are minimal. Do not loosen
Weathertight the pressure port from the body, because leakage could
Explosion Proof result or the pressure switch could be rendered inoperative.
Hermetically Sealed
Dimensions
General
Dimensions are for reference only. Contact the factory for
This instruction provides information for installation, process certified drawings for a particular model number.
and electrical connections, and field calibration of SOR Dual
Design and specifications are subject to change
Hi-Lo Series Pressure Switches.
without notice.
The pressure sensing elements are a pair of force-balanced,
piston-actuated assemblies sealed by flexible diaphragms * 6d
Add O.2S for all non-aluminum ports
and o-rings that are static. The only wetted parts in this
arrangement are the Single pressure port, two sensing
assembly diaphragms and o-rings.
Media pressure on the area of the pistons counteracts the

force of the range spring (adjustable by the adjusting nuts),
which moves the piston shafts only a few thousandths of
an inch to directly actuate the electrical snap-action ~ cji-'~
switching elements.
. ,-,J
Installation HOles "'"-'~~i
'-I ~_J i
.._2771
i - I __ _
Dual Hi-Lo Pressure Switches may be secured to bulk 1lU PrilU";' IQ.l tO~1
heads, panels or pipe stanchions with suitable bolts. Linear mm
4.50 COllnecllon
2.76
When mounting the pressure switch to an irregular or _ _----'in. V1 Weathertight
uneven flat surface, install rubber washers on the mounting
bolts between the housing and the mounting surface.
CAUTION: Failure to place washers between the housing

and the mounting surface may result in torsional forces on
the housing that could cause false trips or render the
pressure switch inoperative. 251.2
9.89
-:t~
Line-mounting by either the process connection or the
electrical conduit connection is not recommended.
CAUTION: Failure to mount the housing on a flat mounting 1~'ll' -.:;.~:

surface may result in torsional forces on the housing that 21 ""'-= J I
could cause false trips or render the pressure switch I //277

process/1._;11 O~--
inoperative. 4 SO Connection 2.7h
V2 Explosion Proof, Hermetically Sealed

For latest revision, see www.sorinc.com
SOR Form 248 (04.01) Printed in USA Registered Quality System to ISO 9001 Page 1 of 2
Electrical Connection
WARNING: Units in hazardous locations-PI-ior to removal from service, make sure that the work area is deciassifed.
Failure to do so could result in severe personal injury or substantial property damage.
Ensure that wiring conforms to all applicable local and national electrical codes and install unit(s) according to relevant
national and local safety codes.
V1 WEATHERTIGHT
Common Normally Open Normally Closed
SPOT: Screw terminal block with marked insulation. Left and right positions.
No.1 (Left side) C1 N01 NC1
No.2 (Right side) C2 N02 NC2
2-SPOT (OPOT): Left and right positions
Nos. 1 & 2 (Left side) C1 N01 NC1
C2 N02 NC2
Nos. 3 & 4 (Right side) C3 N03 NC3
C4 N04 NC4
"V2 Explosion Proof 18" 18 AWG color coded and marked wire leads with 3/4"" NPT (F) conduit connection."
Common Normally Open Normally Closed
SPOT
No.1 (Left side) C1 Blue N01 Black NC1 Red
No.2 (Right side) C2 Blue N02 Black NC2 Red
2-SPOT (OPOT)
Nos. 1 & 2 (Left side) C1 Blue N01 Black NC1 Red
C2 Yellow N02 Brown NC2 Orange
Nos. 3 & 4 (Right side) C3 Blue N03 Black NC3 Red
C4 Yellow N04 Brown NC4 Orange
GR - Ground (Earth) Green wire connected to each hermetically sealed switching element capsule.
NOTE: Transpose NO and NC on vacuum switches when set points are in the vacuum range.
CAUTION: Overtravel has been preset at the factory, i.e. the switching element assembly has been precisely positioned in
the housing for optimum performance. It normally should not be changed in the field. Should adjustment be necessary,
factory approved procedures must be closely followed. Any inadvertent movement or replacement in the field will degrade
performance, void the warranty and could render the device inoperative.
Calibration
a. Remove the housing cover.
b. To increase the set point at which the No.1 (left side) switching element(s) actuates, turn the hex adjusting
nut clockwise with a 3/4-inch open-end wrench.
c. Sight across the flat top of the adjusting nut to the calibration scale at the bottom of the housing for an
approximate set point. Use a 1/4% external pressure gauge to more precisely calibrate the pressure switch.
d. Repeat steps band c for the No.2 (right side) set point. There is no interaction, so it is not critical whether
the left or right side is set first.
e. Replace the housing cover. The pressure switch can be placed in service.
14685 West 105th Street, Lenexa, Kansas 66215913-888-2630 Fax 913-888-0767 www.sorinc.com
Page 2 of 2 Registered Quality System to ISO 9001 SOR Form 248 (04.01) Printed ill USA
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VOITH
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M 14 Attaching parts
14.4 Differential pressure indicator with Switch
14.4.1 Differential pressure indicator

Type: OE1.1 ,2.G.1.P.-2
Indicator pressure difference DELTA P =1,2 bar

Data sheet ............................................ 1614 D
~14,7.1 filter"
"Operating and maintenance instructions - Shutoff valve 30624-4"
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CLOGGING INDICATOR SheetNo
Series OP (visual), OE (visual-electrical) 1614 D
1. Clogging indicator OP-OE
1.1. Type index: (ordering example)

OE1.1,2. G. 1. P. ..~ 1
1 1213141516171
_~J series
OE1 ~ clogging indicator, visual-electrical with 1 contact maker
and contact breaker with 70% switching pressure
difference
OE2 ~ clogging indicator, visual-electrical with 1 contact maker
and contact breaker with 70% and 100% sWitching
plessure difference
OP "clogging indicator, visual
(according to series OE without switching contacts)
~ switching pressure difference: ""p-nominal
f = = 4,5 =4,5 bar

~~-
~
~~-
~~-
0,8 0,8 bar; 1 ,2 1 ,2 bar; 2,5 ~ 2,5 bar;
~ connection:
~~-
~--
'--r-
--- MS. 11 deep
. G = thread according to DIN 3852, T2
---
~--
PG 11
I I V
/ _~ connection size:
1
3
= G Y.
= G Y,
r-·--'t ----i
~ sealing material:
x --c~. ._- P ~ Nilrlle (N8R)
-.- - V ~ VltDn (FPM)
-
co ~J material
rn ~ standard (Ai-execution)
VA ~ stainless steel-execution
f ~J execution
~_Z~_~,____ ~o____J 1
2
= execution 1
= executicn 2
(electrical limit facts see item 3)
(electrical limit facts see item 3)
100
2. Technical data:
permissible operating pressure: 63 bar
permissible operating 8GoC
temperature:
permiSSible pressure difference: p, - P, = 16 bar
view X switching pressure difference '\p: 0,8; 1.2; 2,5; 4,5 bar
70% The electrical signal takes place at 70% of the switching pressure
difference usir-g the design with two contacts the second signal takes
piace 3t 100% 0' the switching pressure difference.
3. Electrical limit facts:

executiDn 1 175V DC, 0,25A, 3 Watt
o
125V AC, 0,25A, 3 Watt
o'" execution 2: 175V DC, lA, 20 Watt
230V AC, 0,5A, 10 Watt
switch-over contact contact maker and contact bceaker
protection: IP 65
30 4. Symbols:
100%
98 execution OEl execution OE2
1+2 contact maker

1+3 contact breaker
EOV 11/96 Changes of measures and design are subject to alterationr
INTERNORMEN - Filter
D-68804 AL TLUSSHEIM Telefon ° 6205 I 2G 94 . 0 Telefax 0 6205/2094 - 40
5. Functioning:
The clogging indicator OE is a combined visual and electrical pressure difference indicator.
This type of pressure difference indicator can be mounted on all pressure filters with operating pressure:; 63 bar. if the
corresponding measuring ports on the filter housing are available.
With contamination of the filter element the difference between the supply pressure and the output pressure of the filter is
increasing. Dependinll on this pressure difference but independent of the operatin9 pressure. visual and electrical signals are
released.
A pressure difference dependent measuring piston. charged with SJPply pressure and output pressure. moves towards a
measuring spnng
Concerning the 01"1 a permanent magnet which is integrated in the measuring piston switches - depending on the gauge
length - a Reed-contact (magnetic switch) and releases electrica! control Signals upon reaching a pressure difference of 70%.
The OE2 is equlped with two magnetic switches which release electrical control signals In a sequence of 70% and 100% of the
switching pressure.
The visual control signal is indicated by a blue-red scale which is connected to the magnetic measuring piston.
In the range of low pressure differences· depending on the gauge le"9th of the measuring piston - the blue range of the scale
appears first.
The indicated switching pressure difference is reached when the dividing line between the red and the blue range of the scale
points to the marking on the display window
6. Operating instruction:
- Connection
Upon connecting the indicator to the filter make sure that the connection marked ,,+" is connected to the d~rt 0.1 side (IN) and the
connection marked ,,-' IS connected to the clean oil side (OUT).
Note: Consider data and connecting conditions mentioned 111 items 2 to 4
7. Maintenance:
The device is maintenance-free. However, make sure that no solvents get In touch with tile display window visual indlco.tor nor
with the piston-spnng·systcm of the clogging indicator
E 16'40
VOITH
14.5 Oil level indicator
Type: 25270/ WEKA
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEKA
ci
z
131
l
principle of cern
level min lhe
Compelled
the current
means
The indication
individual
IB Connecting Of the opposite, 4Y of the indicc

Standpipe south pole is being used to
L~
4A
5
6 Service Flange
t'./ameplate
f'vlagneHc Tope
Clip requirements.
q Installation, eledrical
Themaxlmum switch rating ofWEKAmognetic swHches is indicated on the switch
may;under no circumstances not be exceeded,
The swItches preferably installed opposite the .In cases
distances the switches can to In such a case both
switches have !o be within on of the indication rail.
In you to [ion roils posillorl,do nolforget to reposition the switches too.
The operating principle of Vv'EKA svvitches is bosedon the magnetic field the bar magner. In
no circumstances should iron parts OS scre\vs, monting brocketsJ bolts etc. near or
altached tQ the magnetic level indicator.
A deviation of the magnet field because being too close to the
influence fhe proper function of the level indication oswell osaccessories.
IMPORTANT: Test- and operating pressure as well as operating temperature

as shown on the nameplate 7) of the level indicator may not be
exceeded.
3. Troublcshootinl!
Problem Possible reason Remedy
are
a
in in the
be
iilled up and
- Flocl all po rls.

porls
switches in
indication.
or
WEI{A AG1 Schiirlisfrasse 8, ~ 8344 Biirefswil

Phone +41 (O}43 833 43 431 Fox +41 (0) 43 833 29
il1fo@wekG~Gg.(hf www.welm-ag.ch
VOITH
14.6 Voith electro-hydraulic position control unit
VEHS Description - Operating instructions ............... 3626-015310
- 4/3-way valve with control solenoid
see drawing "Scoop tube control - CW 42591420"
Item no. 0345/0010
- Position pickup
Type: BTL5-E10-M0150-B-KA05
Item no. 0340/0010
Adjusting device (BALLUFF) for position pickup has been placed in junc
tion box for safekeeping.
Illustration 14-35:
Junction box with
adjusting device
a Junction box
b Adjusting device
c Position pickup
with b
d Position pickup
with b
- Position sensor (magnetic ring)
Type: BTL-P-1013-4R
Item no. 034010020
Techn. description of position pickup

and position sensor (magnetic ring) ......... No. 811817 D, version 0110
132
VEHS
VOITN Description - Instruction Manual
Page: 1 /12
Voith Electro Hydraulic Positioning Control
VEHS
Description
5 2001-03-21 R Schott
6 2006-08-02 RSchott
6.1 2007-01-24 R Schott
6.2 2007-06-20 RSchott
U t------t-----I-------i
~. r-------~~----~------~
~ Revision Datum Name
28 August 98/Pt
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- 3626-015 310 en
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VOITM Description - Instruction Manual
Page: 2/12
Contents
Page
1. General 3
2. Operation 3
3. Integrated Positioner Parameter Settings 3
4. Block Diagram of :ioith slectro tiydraulic Po.§.itioning Control 4
5. Technical Data 5
6. Electrical Connection 6
7. Integration of VEHS in Closed-Loop Process Control Circuit 6
7.1 Normal closed-loop process control circuit 6
7.2 Closed-loop control circuit with rapid starting device 7
7.3 Linearization of process variable 8
8. Commissioning of VEHS 8
8.1 Safety information with regard to the VEHS 8
8.2 Setting the position pickup 9
8.3 Setting the electromagnetic actuator 10
9. Options as to the VEHS 11
Appendix A Monitoring procedures of the master process controller 12
28 August 98/Pt
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VEHS
Page: 3/ 12
1. General
The Voith Electro Hydraulic Positioning Control serves to provide an exact and continuous
positioning. The VEHS is used for positioning the scoop tube for geared variable speed
couplings and for positioning the guide vane for torque converters. The VEHS is a compact
unit consisting of an electromagnetic actuator, a double-acting cylinder and the electronic
position pickup.
The actual position is recorded by the electronic position pickup on the double-acting cylinder.
The electromagnetic actuator consists of a control magnet with integrated PIO controller with
subordinated magnetic force control and a hydraulic 4/3-wav valve. The excellent control
quality of positioning control circuit results from the high sensitivity/responsiveness and
accuracy in case of short positioning times.
2. Operation
The VEHS unit is a positioner with PIO action. The actuator (e.g. scoop tube, guide vanes)
is positioned as a function of the position setpoint of a master controller (control circuit).
The internal position control circuit compares the actual position value (position pickup: 4 ..
20 mA <=> 100 % .. 0%) with the position setpoint of the master controller. The deviation
(signal) acts on the subordinated magnetic force controller. The change in magnetic force
F results in an adjustment of way valve (control pin). The control edges of way valve
release an oil flow to and also from the double-acting cylinder.
The position pickup gives a signal of change in piston travel of double-acting cylinder back
to the positioner. A decreasing deviation (w - x) also results in a reduction of magnetic
force F and at w = x the way valve is in the hydraulic center position.
The electromagnetic actuator feeds the actual position (4 .. 20 mA <=> 0 .. 100 %) of
actuator (scoop tube or guide vanes) back. This signal is not electrically isolated and can
be used by the master controller or a local display unit.
To enable the dynamics of positioner to meet the exacting requirements, the electronics of
electromagnetic actuator is designed in analog technology.
The electromagnetic actuator does not include fault monitoring. The master controller is
required to monitor the position setpoint with the actual position value fed back, when all
electrical and hydraulic sources of error are recorded.
3. Integrated Positioner Parameter Settings
The control response of positioner is set via parameter Kp (proportional-action coefficient).

All other parameters are already factory-set and do not need to be changed.
FM: Setting of hydraulic control pin center position at w - x = 0

xO: Control pin setting at s =min, w =4 mA
x1: Control pin setting at s =max, w =20 mA
Kp: Setting of proportional-action coefficient -> increases in clockwise direction
TO: Setting of derivative action time -> increases in clockwise direction
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4. Block Diagram of ~oith slectro .t!Ydraulic Po§.itioning Control
VEHS Unit
r - - - - - - - - - electromagnetic actuator
control magnet 4/3-way valve
I position controller l -- magnetic force _
I I controller I
B A
_ _ _ _ _ _ _ _ _ _ _ _ L __ _
FM
xO x1 Kp,TD FO
; Final controlling element:
F1
Scoop tube
variable speed coupling
191~;
Guide vanes torque converter
X Actual position
feedback:
Wposition setpoint 4 .. 20 mA <==> 0 . 100 %
4 .. 20 mA <==> 0 . 100 %
p1 = Control oil pressure
T = Tank return pipe
A = Consumer
B = Consumer
W position setpoint = Position setpoint of master controller: 4 .. 20 mA <=> 0 .. 100 %
Xactual position = Actual position feedback: 4 .. 20 mA <=> 0 .. 100 %
xO, x1
} Parameter setting through potentiometer
KP, FM
F1 and FO factory-set and lacquered potentiometers are located

TD factory set to minimum } behind the black cap.
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VEHS
VOITH Description - Instruction Manual
Page: 5/12
5. Technical Data
*1 )
Supply voltage - stabilized: 24 VDC ± 15 %
(residual ripple rated load < 1 %)
Maximum current consumption (temporarily): 3.0A
Current consumption during normal closed-loop
control: approx. 1.2 A
Time constant (electrohydraulic conversion): approx. 20 msec
Settling time at 0 <=> 100 % setpoint step change
*2)
at geared variable speed coupling and torque converter: typical 5 - 10 sec
Settling time at 0 <=> 100 % setpoint step change

*2)
at Vorecon: typical 30 sec
Sensitivity of positioning control: < 0.1 %

*3)
Actual position of position pickup: 20 .. 4 mA = 0 ... 100 %
input load 332 0
Analog output actual position feedback - : 4 .. 20 mA = 0 .. 100 %
"Xactual Position" (non-isolated) max. load: 400 ohm
Must not be supplied with 24 VOC (4-wire system).
Analog input for position setpoint - "Wposition setpoint": 4 .. 20 mA = 0 .. 100 %
(from the master controller), mA signal has to be provided max. 25 mA, input load 100 0,
with voltage as usual at a current source. with suppressor circuit
Grade of filtration for control oil: 20 !-1m
Ambient temperature: -20°C ... 80°C
Protection: IP 65
Electromagnetic actuator:
Explosion-proof design to PTB No. Ex-90.C.1065: EExde IIC T 4.
Certificated to CSA and Class I, Divisions 1 and 2,
Groups B,C and D.
Factory Mutal (1Z3A7.AE 0003000967) XP/I/1 IBCO/T 4.
Remarks:
Nominal current consumption is approx. 1.2 A. The 24 VDC auxiliary energy supply line is to be
dimensioned so that the terminal voltage does not fall below the value of 20.4 V on current
consumption. On starting operation or during settling of greater disturbances, current
consumption may temporarily ( 3 sec) rise up to 3.0 A.
'2)
This short settling time is required for the rapid start function. To guarantee a sufficient control stability in
case of a closed-loop control circuit, the master controller is required to output the position setpoint via a
ramp function. In this case it is necessary to set the ramp time as a function of the process.
'3)
Regarding circuit logic the positioner is designed to correct the 0 % position on failure of the position
pickup signal:
xd = Wposilion selpoint - inverted actual position of position pickup. On failure the actual position of position
pickup is greater than 100 %.
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6. Electrical Connection
- The technical data regarding voltages, currents, powers, cable lengths (voltage drop)
and tolerances are to be observed.
- A power supply protection is to be provided by the customer.
- All signal lines are to be shielded.
- Run motor lines and signal lines separately.
- It is mandatory to ground the reference potential of VEHS unit.
- For order-specific information, please refer to project wiring diagram.
7. Integration of VEHS in a closed-loop process control circuit
The Voith Electro Hydraulic Positioning Control shows a very high control dynamics
required for the function of "rapid starting device".
A setpoint change from Wpos = 0 % to Wpos = 100 % is corrected within a short time.
A normal closed-loop process control circuit does not need this high control dynamics. On
account of excellent control characteristics the VEHS reacts very rapidly, without
noteworthy overshooting of actual position (typical 4 % at ~ Wpos 0 .. 80 %).

=
The master process controller is provided with an adjustable ramp function, in order to set
a process-dependent ramp time for the positioning range ~Wpos = 100 %.
If a "rapid startup function" is required, the master process controller is required to switch
off the ramp function for normal closed-loop control during startup.
7.1 Normal closed-loop process control circuit
For normal control applications the master controller must be provided with an adjustable
ramp function in order to match the VEHS to the controlled system.
The different inputs for ramp-up and ramp-down time are to be done by the master
controller.
master controller
~
• ;:p:~ function· normal operation
i (%)
VEHS Unit
T1
ramp-up time
I
100" r~
• "0 '0"'1
,..WPO,",on ••,pa."
>0 . . . .
T2:' I /
ramp.d~ / \
I
I '''': T1 .. ---. T2
•
~ Time I
I
I
I _ _ .J
L -~-
FM
xO x1 Kp,TD FO 'Final controlling element"
F1
rumpas,t'QI.pt "P
2O.4mA- '0,,100%
X Adual pos.lion
_brl
4 ,20mA<,~"'>O __ 100%
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VEHS
Page: 7/12
7.2 Closed-loop process control circuit with rapid start function
"Rapid start function" enable run-up of drive motor virtually at no load at 0 % position
(scoop tube or guide vanes). The master controller is required to output a position setpoint
of 0% to the VEHS unit during drive motor run-up.
When the drive motor reached is maximum speed, the master controller outputs the
required position setpoint abruptly. After reaching the position setpoint , switch over to
ramp function required for closed-loop control. For this purpose the input for ramp-up and
ramp-down time may vary.
The following logic explains the "rapid startup function":
master controller
ram function - normal 0 eration
i•,. ;~p~Ptim..
~ ramp-down time
'f/' ~
[
!.
~
•'\ R
VEHS Unit
I - - - - - electromagnetic actuator
control magnet
- - -
I 4/3-way valve
- I
::;
,~
0, \ I rPositioncontroller, , - magnetic force _
I I I controller
I
I control pin
p1
T
I ...... Tt :. ..... T2 :... ilme
+ I I
ram function - ra id start
F I
I
I
lc I
L
xO x1 Kp, TD
FM
_...... __
I
...J
Unit started - - - - - - j FO Final controlling element·

F1
Motor runup finished & Reset
rom POSI lUll P'C up
20 4mA<:=>O .. 100%
XActualpoSlhon
foodbad<.
4. 20 mA <" .. > 0 HXl%
T1: Ramp-up time - Ramp function
T2: Ramp-down time - Ramp function
T3: Main motor star!
T4: Main motor run-up completed
T5: Changeover from rapid start up ramp function
to the ramp function for normal operation
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VEHS
Page: 8/12
7.3 Linearization of process variable
The VEHS is to be controlled by the process controller using a linearized 4 .. 20 mA

position setpoint signal, when a linear connection exists between position setpoint and
process variable.
Voith Turbo supplies the linearization of position setpoint as option to the VEHS (please see
chapter 9).
Position 5etpolnt
('!o)
100
90
80
70 Position setpoint - VEH The linearization function is to be stored

(linearized)
60 in the master controller or in the supplementary
50
Voith device (option).
40
30
I
Load curve
20
10
Load
0+0~10-20---l-30-40~50~60~70-80-90~10-0 ('!o)
8. Commissioning of the VEHS Unit
8.1 Safety information with regard to the VEHS
1. The 24 VDC power supply for the VEHS should basically be protected against
voltage drop, to obtain a high availability of the complete unit (security of supply,
!:!,ninterrupted 120wer §.upp/y).
2. In the event of the following sources of failure it is standard to move to 0 %

position (a customer-specific 100 % position is also possible):
• if the complete 24 VDC power supply fails
• if the actual position of position pickup (20 .. 4 mA <=> 0 .. 100 %) fails.
• if the position setpoint (4 .. 20 mA <=> 0 .. 100 %) of the master controller

fails.
3. Monitoring procedures of the master process controller.

The VEHS does not perform an internal self-test. It is not provided with an output
"unit ready for operation". The following monitoring procedures can be performed
by the process controller:
• Absolute value: I W position setpoint - Xactual position I is greater than 3 .. 5 %

The VEHS unit does not correct the preset position setpoint within the ramp
time.
• Monitoring of 24 VDC power supply for the VEHS unit.
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8.2 Setting the position pickup

For setting the position pickup separate the electromagnetic actuator from the 24 VDC
power supply. The control oil pressure must be available on the VEHS so that the
final controlling element (scoop tube or guide vanes) can be positioned by the
handwheel of electromagnetic actuator (see page 10).
Please observe the following for balancing the position pickup:
Position pickups of different manufacturers are used in order to observe the required
specifications for the relevant field of application:
a) Position pickup for the non-hazardous area.
b) Position pickup for the hazardous area.
Balancing differs for the relevant position pickup, dependent on the manufacturer.
Please refer, in this case, to the separate instruction manual for the position pickup
attached.
Please observe the following balancing sequence of position pickup in case of all
different manufacturers.
Balancing procedure:
• A current measuring instrument is to be connected in series in the output of

position pickup.
• Move the final controlling element in the zero position of position pickup using the
handwheellocated on the electromagnetic actuator:
Set to the zero point in the zero position of position pickup according to
the instruction manual of position pickup.
• Move the final controlling element to the end position of position pickup using the
handwheellocated on the electromagnetic actuator:
Set to the end pOint in the end position of position pickup according to
the instruction manual of position pickup.
• Check the zero and end position of position pickup repeatedly and rebalance, if
necessary.
• After balancing secure the handwheel of electromagnetic actuator using the

locking bracket.
Zero position End position

Risina sil1nal: I·.. ....
.
output value I actual position output value I actual pos.

4mA I 100% 20mA I 0%
Fal/inll signal:
output value actual position output value actual pos.
20mA 0% 4mA 100 %
._---------,
! I Position pickup rLl ',,----- ..- Magnet - elernet
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8.3 Setting the electromagnetic actuator:
The electromagnetic actuator is factory-set according to the following items 1. to 4.,
so that normally a further setting is not necessary.
The position pickup should already be set for setting the electromagnetic actuator and
the VEHS unit is to be supplied with 24 VOC.
The positioner is set by the four potentiometers on the control magnet:
1. Setting the hydraulic center position of control pin:

• Run the unit warm with the factory setting.
• Check the control oil pressure.
• Preset W position setpoint = 12 mA,
• balance the feedback of actual position using the potentiometer FM
until reaching 12 mA.
2. Setting 0 % position:
=
• Preset W position setpoint 4 mA,
• set the feedback of actual position to the relevant 0 % position using
potentiometer xO.
3. Setting 100 % position:

• Preset W position setpoint = 20 mA,
• set the feedback of actual position to the relevant 100 % position using
potentiometer x1.
4. Optimization of positioner:
• The positioner is optimized using potentiometer Kp
(and perhaps by TO), when presetting W position setpoint steps,
e. g. W position setpoint 2 = 15 mA < W position setpoint 1 = 10 mA. In the event of a too
great system deviation correct the Kp factory setting.
• If the Kp potentiometer is rotated in clockwise direction this results in an
increase of proportional gain of positioner.
Electromagnetic actuator (top view):
1: Handwheel with locking bracket

2: Connector plug
xO, x1, FM, Kp: Potentiometer used for setting
I
--+-4-.
I-J
------,.-----
I
~'!
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9. Options as to the VEHS
1. It is also possible to supply the VEHS unit in explosion-proof design. The following
protection class is observed: EExde IIC T4.
2. A customer-specific auxiliary device can be supplied, in addition to the VEHS unit

with the following options:
• W _Position setpoint limitation:

Adjustable ramp function for separate presetting of ramp-up and ramp-down time.
The acting time limitation performs an electronic damping of final controlling
element.
• Linearization unit:
Conversion of a non-linear process variable to a linear position setpoint function.
• Local control station with selector switch:

- Local/remote changeover switch
- Min. / max. pushbutton for local positioning of final controlling element.
• Check of analog VEHS signal:

- Monitoring of actual position by the position pickup. In the event of a failure
a signal is given to the master controller.
- Monitoring of W position setpoint by the master controller. I n the event of a failure
the last position set point (W position setpoint) is retained.
Technical data of auxiliary device:
The auxiliary device is a programmable controller (S7-214), to be attached directly next

to the VEHS. All parameters are output via a display unit and programmed.
The controller (Siemens S7-214) has the following hardware configuration:
14 binary (24 VDC) inputs 10 binary (24 VDC) outputs

3 analog inputs (4 - 20 mA, 12 bit) 1 analog output (4 - 20 mA, 11 bit)
Supply voltage: 21 ..... 28 VDC / 8 W

Dimensions B x H x T: 250 mm x 80 mm x 62 mm
Operating temperature: 0- 50°C
Technical data of display unit (Siemens OP 3):

Power consumption: 6W
Dimensions B x H x T: 144 mm x 180 mm x 70 mm
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Appendix: A
Monitoring procedures of the master process controller.
The VEHS does not perform an internal self-test. It is not provided with an output "unit
ready for operation". The following monitoring procedures can be performed by the
process controller:
1. Absolute value of 1 Wposition setpoint - Xactual position 1 must be smaller than 5 % within
a specified time.
The process controller must monitor whether the preset 4 .. 20 mA position setpoint
is being reached within e.g. 15 seconds.
The time period depends on the max. VEHS positioning time for 0 % <=> 100 %
position.
However, it should not be selected too small « 10 sec.) to avoid false trippings.
The process controller must form the positive difference of position setpoint and
feedback signal (I W position setpoint - Xactual position I).
- When the difference is <= 5 %, VEHS function is given.
- When the difference is > 5 %, the timer must be started with 15 s operating time.
When the difference is still> 5 % after the timer operation, i.e. after 15 s, there is
a malfunction at the VEHS.
Causes:
- Auxiliary lube oil pump not in operation, control oil pressure not available.
- 4/3-way valve is not adjusted properly.
- Incorrect wiring (e.g. wire breakage).
2. If the feedback signal of the VEHS is > 22 mA, the position pick-up is faulty.
Causes:
- Position pick-up is not adjusted properly.
- Position pick-up is defective.
- Incorrect wiring (e.g. wire breakage)
28 August 98/Pt
C \Documents and SettlngS'irk.My
Documents\Vehs_er1_RevS_2 doc
P.O Box 1555· Telephone (07951) 32-0· Fax 32-500
?~?AP rlnr
BALLUFF
Ci6gli~ Technical Description

BTL5-AlC/ElG__-MlU____-BIZ-S 321KA__ I
User's Guide
BalluH GmbH
Schurwaldstrasse 9
73765 Neuhausen a.d.F.
Germany
Phone +49 (0) 71 58/1 73-0
Fax +49 (0) 71 58/5010
Servicehotline +49 (0) 71 58/1 73-3 70
E-Mail: balluff@balluff.de
http://www.balluff.de
I BTL5-AlC/E/G_ _-M/U_ - - _-B/Z-S 32/KA__
Micropulse Linear Transducer - Rod Style
Contents 1 Safety Advisory
1 Safety Advisory ..................... 2

Read this manual before installing ducer system. In particular, steps
1.1 Proper application .................. 2
and operating the Micropulse Trans must be taken to ensure that should
1.2 Qualified personnel ................ 2
ducer. the transducer system become de
1.3 Use and inspection ................ 2
fective no hazards to persons or
1.4 Scope ..................................... 2
1.1 Proper application property can result. This includes
the installation of additional safety
2 Function and
The BTL5 Micropulse transducer is limit switches, emergency shutoff
Characteristics ..................... 3
intended to be installed in a ma switches and maintaining the per
chine or system. Together with a missible ambient conditions.
2.1 Characteristics ....................... 3
controller (PLC) it comprises a posi

2.2 Function ................................. 3
tion measuring system and may

2.3 Available stroke lengths and
1.4 Scope
only be used for this purpose.
magnets ................................. 3
This guide applies to the model
Unauthorized modifications and
3 Installation ............................ 3
BTL5-NC/E/G ... B/Z... Micropulse
non-permitted usage will result in
transducer.
3.1 Mounting ................................ 3
the loss of warranty and liability
3.2 Transducer, Installation ........... 4
claims. An overview of the various models
3.3 Magnets, Installation .............. 5
can be found in section 12 Versions
1.2 Qualified personnel (indicated on product label) on
4 Wiring .................................... 5
page 12.
This guide is intended for special
5 Startup ................................... 6
ized personnel who will perform the
5.1 Check connections ................ 6
Note: For special versions, which
installation and setup of the system. are indicated by an -SA _ __ des
5.2 Turning on the system ............ 6
ignation in the part number, other

5.3 Check output values .............. 6
1.3 Use and inspection technical data may apply (affect
5.4 Check functionality ................ 6
The relevant safety regulations must ing calibration, wiring, dimensions

5.5 Fault conditions ...................... 6
be followed when using the trans etc.).

6 Calibration procedure .......... 6
6.1 Selecting calibration mode ..... 7
6.2 Teach-in .................................. 7
6.3 Manual adjust.. ....................... 7
6.4 Reset ...................................... 7
6.5 Online-setting ......................... 7
7 Teach-in mode ...................... 8
8 Manual adjust mode ............ 9
9 Resetting all values
(Reset) ................................. 10
10 Online-setting mode .......... 11
11 Technical Data .................... 12
11.1 Dimensions, weights,
ambient conditions ...............

11 .2 Supply voltage (external) ......
11 .3 Outputs ................................
11.4 Connection to controller .......
12
12
12
12
( E: The CE Mark verifies

Emission tests:
that our products meet
RF Emission
the requirements of
EN 55011 Group 1, Class A
EC Directive
Noise immunity tests:
11.5 Included in shipment ............ 12
11.6 Magnets ............................... 89/336/EEC (EMC Directive)

12
Static electricity (ESD)
11.7 Accessories (optional) .......... 12
EN 61000-4-2 Severity level 3
and the EMC Law. Testing in our

Electromagnetic fields (RFI)
12 Versions (indicated on
EMC Laboratory, which is accred
product label) ...................... 12

ited by DATech for Testing Electro
magnetic Compatibility, has con Fast transients (Burst)
firmed that Balluff products meet EN 61000-4-4 Severity level 3
The following patents have been

the EMC requirements of the fol Surge
granted in connection with this

lowing Generic Standards: EN 61000-4-5 Severity level 2
product:
Line-induced noise induced by
EN 50081-2 (emission) high-frequency fields
US Patent 5 923164
Apparatus and Method for Auto

EN 61000-6-2 (noise immunity) EN 61000-4-6 Severity level 3
matically Tuning the Gain of an

Magnetic fields
Amplifier
..AI. I II:I:
I
BTL5-AlC/E/G_ _-M/U_ - - _-B/Z-S 321KA__
2 Function and Characteristics
2.1 Characteristics net to generate a magnetostrictive Dimensions for installing the

torsional wave in the waveguide Micropulse transducer: ... Fig. 3-2
Micropulse transducers feature:
which propagates at ultrasonic Dimensions for installing the mag
- Very high resolution, repeatability speed. net: ... Fig. 3-4
and linearity
The torsional wave arriving at the
- Immunity to shock, vibration, 2.3 Available stroke lengths
end of the waveguide is absorbed in
contamination and electrical noise and magnets
the damping zone. The wave arriv
- An absolute output signal ing at the beginning of the wave To provide for optimum fit in any
- Automatic signal regulation guide creates an electrical signal in application, a wide range of stan
- 100 % adjusting range the coil surrounding the waveguide. dard stroke lengths and magnets in
The propagation time of the wave is various form factors are available.
- Removable calibration device used to derive the position. Depend Magnets must therefore be ordered
- 2 kHz update rate ing on the version the corresponding separately.
- Error information via output signal value is output as a voltage or a cur
rent either with rising or falling char The following nominal stroke
- Pressure rated to 600 bar lengths are available:
acteristic. This process takes place
- IP 67 per lEe 60529 with measuring high precision and Stroke lengths Increments
repeatability within the stroke range [mm] [mm]
2.2 Function defined as nominal stroke length. 50 500 25
The transducer contains a tubular At the rod end is a damping zone, 500 1000 50
waveguide enclosed by an outer within which no reliable signal is
stainless steel rod. A magnet at available, but which may be entered
1000 2000 100
tached to the moving member of by the magnet. 2000 4000 250
the machine or to the cylinder pis
ton is moved over the rod and its The electrical connection between Other stroke lengths on request.
position constantly updated. the transducer, the processor/con
troller and the power supply is via a
The magnet defines the measured cable, which depending on the ver
position on the waveguide. An inter sion is either fixed or connected
nally generated INIT pulse interacts using a female connector.
with the magnetic field of the mag
3 Installation
3.1 Mounting
When possible, use non-magnetiz
able material for attaching the trans
ducerand magnet ring.'" Fig. 3-1.
When attaching the transducer to a

b
magnetizable materials, appro
priate measures must be taken to
protect against magnetic disturb non-magnetizable material
ances ". Fig. 3-1. Note the
4~~
recommended distance of the

transducer and cylinder from
strong, external magnetic fields.
@ b
CD - @ for magnetizable materials a = Spacer made of non-mag

® for non-magnetizable materials netizable materials
b = Magnet
Fig. 3-1: Mounting

I BTL5-AlC/E/G _ _-M/U_ - - - -B/Z-S 32/KA__
3 Installation (cont.)
Damping zone (unusable area)

Nominal 60 ±0.5
= measuring range C\J
d
Magnet Magnet C-
al
(IJ'C
-(0
Thread size: B: M18x1.5 (includes nut) 0 ......
..c: '<t
Z: 3/4"-16UNF 'C x
.!: '<t
iD~
Calibration
device
Fig. 3-2: Transducer BTL5 ... B/Z, Dimensions
Important Installation Notes: not exceed a tightening torque of cylinder rod should be at least
100Nm. 13 mm.
The contact surface of the trans
ducer must be completely con For horizontal mounting of trans When attaching the transducer to
tacted by the mounting surface. ducer with stroke lengths greater magnetizable materials, appropriate
The O-ring supplied must make a than 500 mm, the pressure tube measures must be taken to protect
perfect pressure seal, i.e. the bevel should be supported or attached at against magnetic disturbances,
for the O-ring must be configured its end. -Fig. 3-1.
exactly as shown in Fig. 3-3. When installing in a hydraulic cylin Note the recommended distance of
To achieve secure mounting, use der, do not allow the magnet ring to the transducer and cylinder from
the proper nut for the mounting rub against the pressure tube. The strong, external magnetic fields.
thread. When tightening the nut, do bore diameter in the piston and
3.2 Transducer, Installation Threaded hole

M18x1.5 per min. 25
The smallest permissible distance ISO 6149
between magnet ring and rod max. 2
O-ring 15.4 x 2.1
mounting surface is shown in
Fig. 3-2.
The transducer has either a
M18x1.5 thread or a 3/4"-16UNF
thread for mounting. The sealing is
carried out with the O-ring supplied
at the flange facing. 3.2't> 26 +1
Bevel for O-ring Threaded hole
min. 25
Threaded hole
3/4"-16UNF per max. 1.5
SAE J475
O-ring 15.3 x 2.4
lJ")
lJ")
is)
26 +1
Fig. 3-3: Threaded hole for mounting the BTL with O-ring
I
BTLS-AIC/E/G_ _-M/U - - - - -B/Z-S 32/KA_ -
3 Installation (cont.) 4 Wiring
3.3 Magnets, Installation Note the following when mak The shield must be tied to the
ing electrical connections: connector housing in the BKS
A magnet is required for each trans
ducer. This must be ordered sepa
rately... Fig. 3-4. A ,
•
System and control cabi
net must be at the same
ground potential.
connector (. Fig. 4-3); see in
structions accompanying the
connector.
For mounting the magnet we rec
In the cable version the cable
ommend to use non-magnetizable To ensure the electromagnetic
shield is connected to the hous
material. .. Fig. 3-1. compatibility (EMC) which Balluff
ing in the PG fitting.
warrants with the CE Mark, the
following instructions must be The cable shield must be grounded
BTL-P-1013-4R strictly followed. on the control side, i.e., connected
to the protection ground.
BTL transducer and the control
must be connected using Pin assignments can be found in
L()
N shielded cable. • Table 4- 7. Connections on the
C\J
controller side may vary accord
Shielding: Copper filament
ing to the controller and configu
braided, 80% coverage.
ration used.
3.2
1-------' not used YE (
I
I
I
OV GY
(
BTL-P-1013-4S
10...0 V PK
I
0... 10 V GN
I L() (
C\J '"
N
'"
Q Q~~~~--~
-I-I-
I C\J
GND BU
I +24 V BN
(
BTL5-A11- ~ Controller with
fZJ 4.3 8 ... KA- analog input
Bild 4-1: BTL5-A 11 ... KA__ with controller, wiring example

BTL-P-1012-4R
~
When routing the cable between the ca.S4
transducer, controller and power
supply, avoid proximity to high volt 31
age lines to prevent noise coupling.
Especially critical is inductive noise
8
caused by AC harmonics (e.g. from
phase-control devices), against
which the cable shield provides only
Fig. 3-4: Magnet (optional)
limited protection.
Cable length max. 20 m; 0 6 to
8 mm. Longer lengths may be used
if construction, shielding and routing 020
are such that external noise fields right-angle BKS-S 33M-OO
L() will have no effect on signal integrity. No. 99-5672-78-08 (Binder part no.)
N
C\J
straignt BKS-S 32M-OO

BKS connector, view
~~~'rti~
towards solder side of
3.2 female BKS-S 32M-00
or BKS-S 33M-OO
8
Fig 3-5: Spacer

ca. 62
Fig. 4-2: Pin assignments BKS,
connector type BTL Fig. 4-3: Connector (optional)
I
BTLS-AIC/E/G__-M/U_ - - _-B/Z-S 32/KA__
4 Wiring (cont.)
Output signals
Pin Cable BTLS-A_1 I -C_O I -C_7 I -E_O I -E3 I -G_1
1 YE yellow not used CD I 0 ... 20 mA I 20 ... 0 mA I 4 ... 20 mA I 20.. .4 mA I not used CD
2 GY gray OV
3 PK pink 10 ... 0 V I not used CD I 10 ... -10 V
4 not used
5 GN green 0 ... 10 V I not used CD I -10... 10 V
Supply voltage (external)

Pin Cable BTL5-A/C/E/G 1- BTL5-A/C/E/G2_ CD Unused leads can be tied to
GND on the control side, but they
6 BU blue GND® GND®
must never be connected to the
7 BN brown +24 V +15 V shield.
8 WH white do not connect -15 V ® Reference GND for supply
voltage and EMC!
Table 4-1: Wiring
5 Startup
5.1 Check connections Therefore make sure that no haz 5.4 Check functionality
ards could result from these situa
Although the connections are polar The functionality of the transducer
tions.
ity reversal protected, components system and all its associated com
can be damaged by improper con ponents should be regularly
nections and overvoltage. Before
5.3 Check output values
checked and recorded.
you apply power, check the connec After replacing or repairing a trans
tions carefully. ducer, it is advisable to verify the 5.5 Fault conditions
values for the start and end position
When there is evidence that the
5.2 Turning on the system of the magnet in manual mode. If
transducer system is not operating
values other* than those present
Note that the system may execute properly, it should be taken out of
before the replacement or repair are
uncontrolled movements when first service and guarded against unau
found, a correction should be made.
turned on or when the transducer is thorized use.
part of a closed-loop system whose * Transducers are subject to modifi
parameters have not yet been set. cation or manufacturing tolerances.
6 Calibration procedure
Please note: Any desired magnet position The buttons are automatically dis
within the factory set nominal abled after approximately 10 min
The calibration device is to be at
stroke length can be assigned utes of non-use.
tached to the connection end of
with a null- or endpoint. Do not
the transducer as shown in Advantages:
however reverse the null- and
- Fig. 6-1. Connect the trans
endpoints. The display will always indicate the
ducer to the controller. To monitor
the calibration procedure, a dis Once the calibration procedure is current position value even during
play (controller or multimeter) concluded, the calibration device the calibration procedure.
which displays the BTL voltage or can be removed to prevent acci The last programmed values re
current levels is required. All set dental changes and to store in a main stored, regardless of whether
tings are done with a magnet safe place for the next use. the programming mode is ended
within the stroke area. manually by pressing the buttons
The examples shown in this hand
Please verify that the absolute book refer to the two versions with or automatically after 10 minutes.
null- and endpoints are always o to 10 V and 4 to 20 mA outputs.
within the maximum and mini For all other versions the corre
mum possible output values sponding values can be found in
(- value table 7-1 on page 8). the - value table 7-1 on page 8.
I
BTL5-AlC/E/G__-M/U_ - - _-B/Z-S 321KA__
6 Calibration procedure (cont.)
6.1 Selecting calibration mode To do this, the magnet is brought
alternately to the new start and end
System not running:

position, and the displayed values
Depending on the application use

are adjusted by keystroke or press
either Teach-in or manual adjust.

-, ing the buttons until the desired
I~ _- _- _: ___- _-i.-: __ ~ ~ ~ ~~ System running: values are reached.
In special situations the online set

.. Section 8 Manual adjust mode
ting mode may be used.
6.2 Teach-in
The factory-set null- and endpoints
will be replaced by the new null
and endpoints. First move the mag
.._.
fp@
Move magnet to new desired
);artr~osition.
~I-~¥O=. . .31
-" ,
o ®
net to the new null position, then to
the new end position, and press the

:New start
= Button 1 = Button 2 buttons to accept the correspond
,:value ,
---I--------------;;~
blue gray ing value.
.. Section 7 Teach-in mode before
Fig. 6-1: Calibration device

(shown on transducer) after
1st step: Move magnet to new
null position
Null point
Buttons
disabled
®
=R.$.B . . . . . . .
.Jti-If ult· Move magnet to new
end position
O/@ : Accept new
, null value
- I......
....... ------------------~-
~
' I
/
-~
. •. •. •·. "
- •.·.=.I r,
·--H--·_·
L J
·-1
~'
I
,.~. .
L!
:Newend
, " !'l0~ , :value
Buttons Null :', : before
enabled value : ~ --- ): i a~~; --f---------------------------~~ =.:-~
, , ,
~~§:;/ " ,,
I _ before ,,
after
2nd step: Move magnet to new end
position
-I
End
point
~.
iI -It .....
Accept new:
Fig. 6-4: Manual adjust procedure
end value: 6.4 Reset

----------------- ;=f The reset function can be used to
.. .,.....".
before restore the transducer to its factory
: End
: value
default settings.
after
Buttons .. Section 9 Resetting all values
disabled (Reset)
New stroke 100 %
6.5 Online-setting
Fig. 6-3: Teach-in procedure
Setting the start and end values is
done while the system is running .
6.3 Manual adjust .. Section 10 Online setting mode

This method allows you to set a
new start and/or end value. This
may be useful if the magnet can not
be brought to the null or end point
of the transducer.
Fig. 6-2: Selecting calibration mode

I
BTLS-A/C/E/G__-M/U_ - - _-B/Z-S 32/KA__
7 Teach-in mode
Enable buttons: BTL5-A... with magnet in stroke range

1. Press one of the buttons for at
Displayed values (example)
least 3 s. Release button.
for 0 ... 10 V for 4 ...20 mA
2. Within 1 s hold down buttons 1+2
simultaneously for at least 3 s.
Now the Error value remains stored
en
c
0
S. 3 9 II
I 9.1 S nRI value
Current position
as the output signal.

In case of an error or a break in
>3s =
:::I
.c
O/®4 S. 3 9 1111 9.1 S ,~ RI Current position
value
<1 s
.!!
the activation sequence of but .c
ca 10. SO II 3.60 CRI Code =Error value
tons, wait for the duration of pro- c I
tection time of 12 s before start w
ing the sequence anew. 10. S a II 3.60 .0 RI Code:::: Error value
I
Select teach-in:
Hold down button 1 for at least 2 s 1..1. a a II 12.00 nRI Code for Teach-in
until the code for teach-in is dis
played. Release button. Der aktuelle
Positionswert wird angezeigt.
S.39 II 9.1 S ,~ RI Current position
value
Set nullpoint:
Current position
1. Move magnet to exact desired 1.0Y III Y.82 nRI value
nullpoint.
2. Hold down button 1 for at least = Null value
2 s. The new nullpoint is set.
>2 s 0.00 II Y.OO CRI Code
Set end point:
3. Move magnet to exact desired end 0.00 II Y.OO oRI New null value
point.
Current position
4. Hold down button 2 for at least 9.89 III 19. 1 3 "RI value
2 s. The new end point is set.
End teach-in 10.00 II 20 .00 nRI Code = End value
and disable buttons:
Hold down buttons 1+2 simulta- 10.0 a II 20 .00 "RI New end value
neously for at least 6 s to end the
calibration procedure until the Error
value is displayed. Then press one en
c >6 s ( 10. SO II 3.60 CRI Code =Error value
0
of the buttons briefly to disable both
buttons. =
R:::I
"" I
~'II
'tI.c
w_
cG) <1 s O/®...j 10. SO 3.60 cRI Code =Error value
~
Check your new settings carefully .c
ca Current position
before you start up the machine VI 10.0 a vl.1 20.00 "RI value
or system. :s
Table 7-1: Value table for ~;" NUli po;n' . .~

End point
teach-in and manual adjust
Value table for BTL5 Min. Null value Code for Code for
teach-in
I
End value
(rod end)
\* Max. Error
value
teach-in and adjusting version value (head end) adjusting value

rising A (Volt) -0.50 0 2.00 4.00 +10.00 +10.50 +10.50
G (Volt) -10.50 -10.00 2.00 4.00 +10.00 +10.50 +10.50
B (Volt) --5.25 --5.00 2.00 4.00 +5.00 +5.25 +5.25
C (mA) 0 0 6.00 12.00 20.00 >20 >20
E (mA) <4 4.00 6.00 12.00 20.00 >20 <4
falling A (Volt) +10.50 +10.00 B.OO 6.00 0 -0.50 -0.50
G (Volt) +10.50 +10.00 B.OO 6.00 -10.00 -10.50 -10.50
(
B (Volt) +5.25 +5.00 B.OO 6.00 --5.00 --5.25 --5.25

C (mA) >20 20.00 14.00 8.00 0 0 >20
E (mA) >20 20.00 14.00 B.OO 4.00 <4 <4
RALLUII=II=
I
8 Manual aQjust mode
Enable buttons: BTL5-A. .. with magnet in stroke range
1. Press one of the buttons for at

Displayed values (example)
least 3 s. Release button.

forO ... 10V for 4 ...20 mA
2. Within 1 s hold down buttons 1+2
simultaneously for at least 3 s. Now 9.15 Current positlon value
the Error value remains stored as til "AI
e
the output signal. 8:::s 5.39 9.15
"AI Current position value
Select adjust: .Q
Hold down button 2 for at least 2 s .!!
.Q 3.60 OAI Code =Errorvalue
until the code for manual adjust is III
displayed. Release button. The cur e
W
rent position value is displayed.
3.60 nAI Code = Error value
Adjust start value:

1. Move magnet to exact start posi 6.00 Code for adjustment
tion. "AI
2. Hold down button 1 for at least 2 s.
3. Shift null point (=start value) to 9.15 ., AI Current position value
wards flange or rod end with con
stant slope: Briefly pressing the
buttons increases or decreases the 1.0Y Y.82 ,AI Current position value
actual value by approx. 1 mV or 2
IJA. Holding a button down for Code for adjusting
>2 s Y.OO
longer than 1 s increases the step "AI start value = Null value
size.
4. Exit calibration procedure for the Y.82 OAI Current position value
start value: Press buttons 1+2 less
than 2 s. Y.YO OAI New start value
Adjust end value:
5. Move magnet to exact end posi
tion.
6. Hold down button 2 for at least 2 s. -I 2.00 6.00 ., AI Code for adjustment
7. Increase or reduce slope: Briefly
pressing the buttons increases or
decreases the actual value by Y.YO "AI Current position value
approx. 1 mV or 2 IJA. Holding a
button down for longer than 1 s
increases the step size.
1g. 13 ., AI Current position value
8. Exit calibration procedure for the
Code for adjusting
end value: Press buttons 1+2 less 20.00 oAI end value = End value
than 2 s.
19.13 Current position value
Additional notes: "AI
Setting the end value (i.e. the slope)
and the start value can mutually
affect each other depending on the 19.0 a "AI New end value
stroke position. You will need to
repeat steps 1 to 8 over until the
start and end values agree with their
respective desired values. 6.00 Code for adjustment
"AI
End adjustment, disable buttons:
Hold down buttons 1+2 simulta
neously for at least 6 s to end the
9.00 ~II 19. 00 OAI Current position value
calibration procedure until the Error

value is displayed. Then press one
~'II
1/1
of the buttons briefly «1 s) to dis
able both buttons.
c
8 + 2.+1 10.50 3.50 ,A I Code = Error value
:::l
<1S01~
~
'"C.c 10. SO
Check your settings carefully be e CI.)
w_ ·,11 3.60 "AI Code::: Error value
fore starting up the system. .c
~'II
III
1/1 9.00 19.00 ' AI Current position value
:0 ®-I
Ii Q
I
9 Resetting all values (Reset)
If an existing configuration needs to Displayed values (example)

be deleted, all values can be re atO... 10V at 4 ...20 mA
stored to the original factory set
Current
tings (Reset). 5.39 V 10.80 MRI position value
I/)
Activate buttons: c
,~ RI
0 Current
1. Press one of the buttons for at § 5.39 10.80
least 3 s. Release button. .c
vi position value
2. Within 1 s hold down buttons 1+2 G)
Code=
simultaneously for at least 3 s. Now :25 10.50 1/
3.60 MRI
CIS " Error value
the Error value remains stored as c
W
the output signal. Code =
10.50 V 3.60 n RI Error value
If an error occurs or there is an ...
G)
interruption while activating a II) Code =
G) 0.00 1/
" Y.OO MRI Null value

button, please wait for an addi- a:
tional 12 s before starting over.
Current
8.Y 3 VII 15.61 MRI position value
Perform reset:
(factory setting)
3. Hold down both buttons for at least
6 s. The Null value is displayed, and
the reset has taken place.
4. Release buttons. The current posi
tion value is displayed and the
buttons are again deactivated.
The transducer is ready for new
calibration.
I
10 Online-setting mode
The BTL output signal at a particu

lar magnet position is set to the CAUTION! In this procedure the machine with the BTL system remains
desired value which is then stored operational, i.e., any change in the BTL output signal may
by the controller as a start or end cause the machine to respond.
value without having to power down Be sure that this response will not result in any risk to persons
the entire system. For this reason or equipment!
the safety advisory at right should
be especially noted. Maximum adjusting range for each adjustment procedure:
Start value = max. ± 12.5 % of actual stroke,
Setting start value online: End value = max. ±12.5 % of actual output value.
1. Position system so that the mag

Note: Between each adjustment procedure - also between setting of start
net ring is located at the start posi
and end value - has to be exited by waiting 15 s (time out) until the next
tion.
adjustment can be carried out.
2. Activate buttons:
Hold button 1 down for at least 3 s When the desired value cannot be reached within the first adjustment pro
and then - without releasing but cedure because the adjustment range of ± 12.5 % is exceeded, another ad
ton 1 - hold both buttons down for justment can be carried out after 15 s. This can be repeated until the de
at least 3 s. sired value is achieved.
3. Setting the value:
Briefly pressing the buttons in
creases or decreases the actual BTL5-... with magnet in start position
value by approx. 1 mV or 2 flA. Displayed values (example)
Holding a button down for longer at 0... 10 V at 4 ...20 mA
than 1 s increases the step size. current
4. Once the adjustment range or the 5.39 Ii position
desired start value is reached, the value
setup mode is automatically exited
if no button is pressed for at least
15 s. The buttons are again dis
abled. Another adjustment proce current
dure can be carried out. 5.39 Ii position
value
Setting end value online:
1. Position system so that the mag
net ring is located at the end posi
tion.
2. Activate buttons: new start
Hold button 2 down for at least 3 s
Y.8Y value
and then - without releasing but
ton 2 - hold both buttons down for
at least 3 s. The values shown here are examples only.
3. Setting the value:
Briefly pressing the buttons in BTL5-... with magnet at end of stroke
creases or decreases the actual Displayed values (example)
value by approx. 1 mV or 2 flA. at 0 ...10 V at 4 ...20 mA
Holding a button down for longer current
than 1 s increases the step size. position
4. Once the adjustment range or the value
desired end value is reached, the
setup mode is automatically exited
if no button is pressed for at least
15 s. The buttons are again dis
current
abled. Another adjustment proce
dure can be carried out. 8.12 Ii position
value
new end
9.Y 9 19.18 value
The values shown here are examples only.
. h
IBTLS-A/C/E/G__-M/U_ - - _-B/Z-S 32/KA__
11 Technical Data
Typical values at DC 24 V and 25°C. Ready for operation at once, full accuracy after warm-up. With magnet
BTL-P-1 013-4R, BTL-P-1 013-4S or BTL-P-1 012-4R:
Resolution_ + Hysteresis 11.1 Dimensions, weights, 11.3 Outputs

Repeatability ambient conditions
BTLS-A. ..
Voltage 0.3 mV
Nominal length ~4000 mm Output voltage 0 ... 10/10... 0 V
Current 0.6 (JA
Dimensions .. Fig. 3-2 Load current ~5mA
Minimum 0.05 mm
Weight ca.2 kg/m Ripple ~5 mV
Sampling rate fstandacd = 2 kHz Housing anodized aluminum BTLS-G...
Pressure tube Stainless steel 1.4571 Output voltage -10...10/10... -10 V
Non-linearity
diameter 10.2 mm Load current ~5 mA
Nom. length ~ 500 mm > 500 mm
wall thickness 2mm Ripple ~5 mV
in (Jm ±100 ±0.02 % FS e-modulus ca. 200 kN/mm 2 BTLS-C...
Temperature coefficient Mounting thread M18x1.5 or Output current 0 ... 20/20... 0 mA
3/4"-16UNF Load resistance ~500 Ohm
Voltage output:
[150 (Jv/K + (5 ppm/K • P • V/NLl] • ~T Operating temp. -40°C to +85 °C BTLS-E. ..
Current output: Humidity < 90 %, non-dewing Output current 4 ... 20/20.. .4 mA
Protection rating Load resistance ~ 500 Ohm
[0,6 (..IAlK + (10 ppm/K * p. I/NLl] * ~T
V = output voltage range in [V] per IEC 60529 IP 67
I = output current range in [mAl with connector attached 11.4 Connection to controller
NL = nominal length in [mm] Analog interface:
~T = temperature coefficient in [I<] 11.2 Supply voltage (external)

With S32 connector for shielded
P = magnet position in [mm] Regulated supply voltage cable (max. length, see "Wiring"),
Shock 100 g/6 ms BTL5-_1 ... DC 20 to 28 V diameter 6 to 8 mm, or with integral
,-
per IEC 60068-2-27 1 Ripple ~ 0.5 Vpp cable (5 m long) ,-

BTL5-_2 ... DC ±14.7 to ±15.3 V co
Continuous shock 100 g/2 ms OJ
per IEC 60068-2-29 1 Current draw ~ 150 mA 11.5 Included in shipment c
Inrush ~ 3 AlO.5 ms
o
'';::::
Vibration 12 g, 10 to 2000 Hz Transducer .. Fig. 3-2
Polarity reversal protection built-in ii
per IEC 60068-2-6 1 Calibration device .. Fig. 6-1 Q)
(take care to avoid inherent reso Overvoltage protection en

Q)
nances of protective tube) Transzorb diodes (J
11.6 Magnets ell
Pressure up to 600 bar Electric strength 0..
GND to housing 500 V (order separately) Q)
when installed in a 0::
hydraulic cylinder Magnets BTL-P-1013-4R, •
1 Individual specifications as per
BTL-P-1 013-45, BTL-P-1 012-4R ~
Balluff factory standard Dimensions .. Fig. 3-4 OJ
Weight approx. 10 g @
Housing anodized aluminum f5
Operating temp. -40°C to +85 °C .8
+-'
Magnets BTL5-P-4500-1 (J
Q)
12 Versions (indicated on product label) (Electromagnet) ii'
:::J
Weight approx. 90 g en
I Supply voltage: 1 = DC 24 V, 2 = DC ± 15 V
Housing plastic ~
I --..r:::::- Electr. connection, S 32: with connector,
Operating temp. -40°C to +60 °C 0
~
~T~5-A11-Ml0450-~ Rod Style, KA05: with 5 m cable (J
;;::
11.7 Accessories (optional) 'uQ)
:; g Mounting: B = metric thread M18x1.5
e1ilffi includes nut
Z = thread 3/4"-16UNF
Connectors .. Fig. 4-3 c.
en
.S:;! 0'
~t= ,-
,-
m Nom. length (4digits): M = metric in mm o
c U = inches in 1/10 Inch c
o
:.J '';::::
Analog interface:
ii
Voltage output A_ 1 = 10 ... 0 V and 0 ... 10 V
w
G_1 = 10 ... -10 V and -1 0 ... 10 V
•
I
Current output C_O = 0 ... 20 mA E_O = 4 ... 20 mA w
r--.
CJ = 20 ... 0 mA E_7 = 20 ... 4 mA ,-
co
,-
co
c:i
Z
VOITM
Voith Turbo I Geared variable speed coupling I SEC S61ndonesia Pelabuhan I R 15 K 400 M 14 Attaching parts
14.7 Duplex filter with filter element
14.7.1 Duplex filter
DU631 631.30801.25G.30.E.P.FS.9.
Drawing ........................................... .42013310
Operating and maintenance instructions
- Duplex filter ......................................... 20320-4
Operating and maintenance instructions
- Shutoff valve ......................................... 30624-4
14.7.2 Filter element
Voith Artie! e No.: 4221 881 0
Type: 01 NL.630.25G.30.E.P
133
~
Entlueftung GII2/ I tei Ie
AIR BLEEDING GI/2 ~
PARTS
I ,I ueck Benennung Abmessung Art ikel-Nr. !
4
JSS
~~
,
:!i ~~ Y.
2
2
DESIGNATION
Fi I \erelement I FILTER EL[IA[NT

O-Ring / O-RING
OIi<[NSION
01N.630
14 x 2
ART ICLE -No.
(IIIlR)
Ql
1
~
, I t .~ 2 a-Ring / O-~ING 60 x 3,5 (IIIlR) 1
2 a-Ring / O-RING 125 x J (IIIlR)

I
, 1 a-Ring / O-~ING 24 x .3 (IIIlR)
, 2 O-Ring I O-RING 115 x J (IIIlR)
1 a-Ring / O-RING 96 x 4 (IIIlR)
1 O-Ring / O-RING 32 x J, 5 (IIIlR)
2 a-Ring / O-RING 69.45 • 3.53 (IIIlR)
4 Verschlussschroube / SCREW PLUG G ./2
~ 4 Verschlussschraube I SCREW PLUG G 1/4
En tteerungs- u. Ent! ueltunqsan~ch Iuss, gesch Iossene Pas i t I on Nassblott
EVACUATION 00 BLEEDER-CON<ECTION; CLOSED POSITION SHElT -No. 33639-4
l~ ~ F= 1 Absperr~entit AV.G.'.-.P.VA
Nassblott
J0624-4 420,6)7 0
SHUT -Off VALVE SHElT -No.
------~~tt--~--~HH~~- ~~ ~2~--0~'~Ch~'-"-nq~/~~~S~KE~T------------------_+----~~~--_+--------~
~ 2 Packung / PACKING
AlB 22 x
- ~~'~~~~~2__t-~0~'C~"~I~n9~/~A~~l~AR~BE=Z=EL~____________~____~~~__-+________-,
,~ ~~2~--V~'~nl~I~I~/~V~'L~VE~-,---,-,~----------t---~~~----t----------
'V.ONS
~ _'----'_0_'_"'_'_'"_59'-'_''_'h_5_,,_n_,'_'_I_P_R'__S_SU_R_E_B._L_ANC_E_V._L_VE__L..___________L.._ _ _ _ ____
1
Technische Daten
TECHNICAL DATA
T~eroturbereich -1O'C bis .. 80·C (kurzzei tiq .. lOO·C)
TEII'ERATURE RANGE' -1O"C TO • 80'C (fOR A SHORT TIUE • 100-C)
Uoximoler 8etflebsdruck : 32 bar
UAX. OPERA TI NG PRESSURE ,
PrueldrlJck . 42 bor
TEST PRESSURE
AnschllJsssys\em Flonsch SAt 2 1/2 J:)IBt; 3000 PSI
CONNECTION SYSTEN , FLANGE SA£ 2 1/2 J516c 3000 PSI
~~~~e:+~~: ~~
01 chtungsmo ter I aI
: GGG 40.3
PerbUMn (NBR)
SEALING WATERIAl NITRIL, (NBR)
Ei nboulaqe . senkrecnl
It\STALLATION POSITION VERTICAL
Fuellmenge : 2x6.41
fiLl! NG
S i nnb i Id
SYMBOL
'--G·'
I
I
I
--
.
__
I
I I
I!
!
,- -
I,
Slellung
Ste Ilung
POS I . L
POS II * DOUBLE FILTER
WI TH SHUT-Off VALVE
Manual and maintenance instructions Sheet No.
for INTERNORMEN pressure filters, change-over 20320·40
DU 63, 101, 251,401,631,635, 1001, 1950, 1050, 2050, related specifications Page 1/3
This manual is effective for all filters of the type DU 63, 101, 251, 401, 631, 635, 1001, 1950, 1050, 2050 and related specifications. It
contains certain requirements and instructions which ensure unobjectionable operation of the filter. It can be completed with specific
additional instructions by the operator himself if necessary.
1. Safety instructions
- Prior to operating the filter, manual and maintenance instructions have to be read carefully.
- Follow the instructions of this manual under any circumstances!
- The manufacturer does not assume liability for any damage, which occurs due to disregarding these instructions.
- If operations are carried out differently, the safety of the pressurized device can not be assured!
- Operating conditions given in the data sheet, especially excess pressure, temperature range and operating fluid, have to be followed
unconditionally. Variation of these parameters can cause damage to important pressure holding parts and sealing. Also take in
consideration the compatibility of filter components with the operating fluid.
- Under working conditions the filter housing is pressurized. Do not try to loosen or remove any part of the filter or the filter housing
during operation. The operating fluid could escape at high pressure and high temperatures.
This does not apply for parts of the decompressed or the turned off side of the filter (see "Maintenance").
- Leaking operating fluid always bears the danger of injuries and burns!
- Do not open the filter housing until you made sure it is not pressurized any more!
- Touching parts of the filter may cause burning, depending on the operating temperature.
- When exchanging the filter keep in mind that it might have operating temperature. Danger of burning!
- Always wear safety goggles and gloves when working on the filter!
- If you come into contact with the operating fluid please follow the instructions of the fluid manu facturer!!
- Only use original spare parts.
For filters being used in hazardous locations the INTERNORMEN documentation N" 41269 "Supplementation of the Operating Manual
for the use of filters in potential explosive areas.
2. Installation
Note safety instructions!
When removing a new filter from its box it is ready for installation. It is placed on a level area and attached (DU 63) or screwed
(DU 101-2050) to it.
Afterwards remove protective caps from connections and connect those to the present pipe work.
Appropriate pipe work (pipes, hoses) ensures that drain and air-bleed valves are connected to proper containers. For these purposes
original INTERNORMEN drain and air-bleed valves can be used.
When installing the filter please make sure, that:
- sufficient fixation of the filter is assured
- the clogging indicator is accessible and can be checked easily.
- the connections for draining, air-bleeding and pressure measurements can be accessed easily.
- there is enough room above the filter to remove and replace elements.
- no dirt, particles, other contamination or fluids enter the filter.
- both inlet and outlet of the filter are connected to the pipe work correctly.
- counterfianges or screw joints of the pipe system and the filter have to be angled precisely and connected that same way
(if counterfianges or pipe joints are canted or under tension switching filters can be aggravated and it might harm pressure
tightness)
Fitting the counternanges for DU 101-2050
1'.l+r)) \ I / V ~ 1,. "\ 1 r .~
1![;i /\ ti t ISll !~
Q
1) connection for the potential equalisation.
only for application In the explosive area
i
~
wrong correct
- the following torques have to be applied when fastening the counterfianges
Type DU 63* DU 101 DU 251 DU 401 DU 631/635 DU 1001/1950 DU 1050/2050
Connection 0/.," 1" I 1 Yo" 1 W' I 2" 2" 2 'h" 3" 4"
Moment [Nm] 100±15 10±2 112.5+3 25+5 1 28+6 28+6 40 +8 71 +15 100 +25
- sufficient measures were taken to prevent corrosion.
- the filter is protected from other mechanical influences (such as impacts and hits).
EDV 08/04 - Englisch
~
Friedensstrasse 41, 68804 Altlussheim, Germany
internormen - phone
f:::lY
+49 - (0)6205 - 2094-0
.... ,dQ _ tn\R?nl=\ _ ?nQ~LA.n
e-mail
11rl
sales@internormen.com
\AMon", iMfn.I"'I"'I ..... I"..,..,~1"'\ ,...,.. .......
~
for INTERNORMEN pressure filters, change-over 20320-40
DU 63,101,251,401,631,635,1001,1950,1050,2050, related specifications Page 2/3
3. Initial operation
3.1 Prior to initial operation
Prior to the initial operation of the system or the machine, which means prior to filling in any fluid, check the internal condition of the
filter. Proceed as follows:
- Open the filter housing by removing the lit. Check the cleanness of the housing, the presence of an element, the sealing, etc..
- Close the housing tight.
3.2 Filling and air-bleeding
Prior to the initial operation, the filter has to air-bleed as follows:

- Turn the switch of the filter to the middle position. The lever of the OU 63/635/1050/2050 is right in the middle between the two stops.
The stop-pin of the DU 101-1950 also is positioned right between the two stops.
- Fill both sides of the filter using the regular operating fluid flow.
- Open the locking screws on the side of the top edge of the filter (OU 63) or on top the filter lit (OU 101-2050). Wait until it leaks fluid
without any bubbles and there is no more sound of air escaping.
- afterwards tighten the locking screws again.
After this process you can direct the flow of the fluid, which is supposed to be filtered, to pass through either side of the filter. This is
done simply by turning the lever or the switch. To recognize which side is operating at the moment, just note the following:
OU 101/251/401/631/1001/1950: The stop-pin of the switch is pointing at the side which is operating at the moment.
OU 631635/1050/2050: The lever itself points at the side which is operating at the moment.
the illustration corresponds to DU 101/251/4011631/1001/1950 the llustratlon corresponds to DU 635/1050/2050
shut-off valve
stop motion devices
screw at bottom for pressure balancing
air bleeding screw
of filter bowl
in the lid
stop motion device stop motion device
air bleeding screw

for pressure balancing in filter bowl
left pas .• filter opened left pos .... filter closed
right pas.·filter opened
left pos.-filter opened right pas .• filter closed
right pas.-fHter closed left pos.-filter closed
stop pin in middle position,

stop pin in middle position,
left and right filteropened;
left and right filteropened,
No ol*'Qtng lIIat. I No CJ!:*'aHng atat. I
tM Hlu.llratlon ClIITHpOnda to DU 63
stop motion devices
air bleeding screw air bleeding screw

in filter bowl in filter bowl
for pressure balancing
stop pin in middle position.

left and right filter opened,
No ap.raHng .tat. I
Friedensstrasse 41, 68804 Altlussheim, Germany

internormen phone +49 - (0)6205 - 2094-0 e-mail sales@jnternormen.com
) <; - I.
for INTERNORMEN pressure filters, change-over 20320·40
DU 63,101,251,401,631,635,1001,1950,1050,2050, related specifications Page 3/3
4. Maintenance !Inspection
Also please note all particular site-related instructions for inspection.
Using filters equipped with clogging indicators it is necessary to exchange or clean the element if the signal "Clogged filler" is emitted
(also note the data sheet or the instructions of the clogging indicators).
Contaminated elements have to be replaced as soon as possible! If a clogged element is not removed it may cause severe damage to
the entire system!
Attentionl
Always exchange elements with sealing. If a cleaned metal mesh element type "G" is reused replace its sealing. The exact
markings can be found in spare part lists for each element.
4.1 Replacing the filter element
Maintenance or the exchange of contaminated filter elements has to be performed as follows:
- Open the shut-off valve for pressure equalization.
- Switch the filter to the opposite side.
- Close the shut-off valve.
- Open the air-bleed valve of the discharged side of the housing in order to equalize the pressure with the surrounding atmosphere.
- Open the drain-valves to drain the filter
- Open the lit of the discharged side of the filter housing.
- Loosen and remove the element by light swaying and pulling.
- If necessary cover or close the adaptor end inside the housing and clean the entire inside.
- Close the drain valve and remove the cover of the adaptor end if present.
- Check the sealing of the filter lit and replace the a-ring if necessary.
- Take the replacing element, make sure the serial number matches the number of the old element, and insert it into the housing
(prior check if the elements sealing are undamaged and tighten them)
- Close the filter with it's lit.
- finally perform the steps described in 3.2 "Filling and air-bleeding"
4.2 Cleaning the filter element

Metal mesh filter elements can be recycled after cleaning. This cleaning procedure can be performed based on the cleaning instructions
for INTERNORMEN metal mesh filter elements on sheets no. 21070-4 and 39448-4.
When removing and reinserting the element please proceed as described in 4.1 "Replacing the filter element".
The maintained side of the filter is now ready to operate at full strain again.
In addition to that it is possible to maintain or replace the clogging indicator if necessary. Both the DU 101 and the DU 251 separate this
device from the pressurized system when it's switch is brought into the middle position.
Attention!
Independent from a necessary change ofthe element, the switching armature has to be actuated at least once per three weeks
in order to maintain full operatibility.
5. Additional information
In addition to the regular clogging indication, the pressure drop, which is evidence for contamination, can be monitored and checked.
On filters OU 101-2050 certain miniature measuring devices with a G Y. A inside thread can be connected to the flanges. For this
purpose it is necessary to install measuring connections with M16 screw joints.
6. Service
The service will be performed by
INTERNORMEN GmbH phone: +49(0)6205-2094-0

Friedensstr. 41 fax: +49(0)6205-2094-40
0-68804 Altlussheim e-mail: info@intemormen.com
Germany uri: www.intemormen.com
Special questions about the operation of the filter will also be answered within this area.
Spare parts respectively wearing parts have to be ordered according to the spare part list of the filter-data-sheet.
internormen Friedensstrasse 41, 68804 Altlussheim, Germany

phone +49 - (0)6205 - 2094-0 e-mail sales@internormen.com
+ rl
STOP VALVE Sheet No.
Series AV ON 5 PN 100 30624-48
1. Type index: (ordering example)

48"
12.5 23
AV. G. 1. -. P. VA
1112131415161
-1J series
AV stop valve
...2.J connection:
2 G thread according to DIN 3852. T2
2J connection size"
1 GY
....!.J execution
~I ~ Z
cannot be interlinked (R3 and 53 not present)
intermediate plate interlinking. interlinked with clogging indicators according to sheet-no. 1609. 1628, 1629
I III I or clogging sensors according 10 sheet-no. 1607. 1608
--2J
sealing material:
In P Nitrile (NBR)
'"'"
V Vilon (FPM)
~ housing material:
standard (AI-<lesign)
VA stainless steel-execution
width
across 17 width across 3
pressure relief E
connection 53 and R3 only for
2. Technical data:
intermediate plate construction
temperature range: -10"C to +80"C (for a short lime +100"C)
max. operating pressure: 100 bar
max.pressure difference: 100 bar
166
50
I--!--I 3. Spare parts:

. I .
~r--r--T'l.
I IIF-=~ I
··~I~I~
item qtv. desiQnation dimension article-no.
1 2 valve AV.DNS 316344
2 2 O-ring 14x2 304342 NBR 304722 FPM
3 2 ball 4.762 316377
L_ I -~ 4 2 set screw M6x 12 316368

5 2 annular beeel 316371
6 2 packing 316370
weight: approx. 1.8 kg
Changes of measures and design are subject to alteration!
internormen II Friedensstrasse 41, 68804 Altlussheim, Germany

phone
fax
+49 - (0)6205 - 2094-0
+49 - (0)6205 - 2094-40
e-mail
uri
sales@internormen.com
www.internormen.com B
Symbols: 7. Operating instructions:
Depending on the order, filters are normally fitted with the shut-off valve before delivery. During retrofitting care must be
exercised to ensure that the sealing elements, O";ng 14x2 are there and seated correctly and that there is cleanliness
hydraulic symbol
during inslallation.
cannot be interlinked intermediate plate inteninking Operation depends on the operational condition:
51 R1 51 Rl a) Operating condition of the shut-<>ff valve
Valves AS and AR open, p, and p, operate the contamination indicator.

- Valves ES and ER closed.
521 • .152 521 • .152 b) Cutting-<>ff operation of the shut-<>ff valve

Close valves AS and AR, turn the valve spindle clockwise up to the stop, torque approx. 1-2 Nm, p, and p,
R2 I. • R21. • IR2
remain active on the indicator.
Open valves ES and ER 1 tum anti-dockwise on the M6x12 stud (tool. 3 mm Allen key), p, and p, on the
indicator go to 0, which means that the existing pressure is released through relief connections E.
E E E 53 R3 E
Dismantling or exchange of the connected contamination indicator is possible.
c) Test operation
Close valves AS and AR (see point 7b)
Open valves ES and ER (see point 7b)
· Connection configuration: - Close valve ES (see point 7d)
esciiPtion of the co nnection eQuipment connection pressure Connect external test equipment to S2
S1 filter connection dirt Side p,
R1 filter connection clean side p, Provide the test pressure to 52 and check the operation of the connected indicator. Test pressure:;::
S2 indicator pipe connection dirt side p, switching pressure differential.
test connection
R2 indicator DiDe connection clean side
Release the test pressure, remove the external test equipment and seal connection S2.
0,
S3 indicator intermediate plate connection dirt side p,
d) Establishing the operating condition
R3 indicator intermediateplate co nnection clean side p,
E rel!eving connec~&ns_ _ ,,-=0_ After an exchange or test of the connected contamination indicator the operating condition must be re-established.
--------- - -
Clock valves ES and ER, turn the M6x12 stud clockwise up to the end stop, tighten to approx. 0,5-1 Nm
Open valves AS and AR (see point 7b)
Warning I
With valves AS and AR closed and valves ES andlor ER open, the valves AS and AR will not shut off if there is a constant
leak at connections E.
· Description: The connected contamination indicator or the sea! at connection S2 must not be dismantled if it is impossible to establish
the closing operation of valves AS and AR.

1e AV shut-Off valves, intendend for use in double filters with change-over valve,that can be serviced during operation and
ed with a contamination indicator.

• check or exchange the contamination indicator, it is necessary to shut off the pressure feed pipes S1 (contaminated side) 8. Maintenance:
Id R1 (clean side) between the contamination indicator. Valves AS and AR meet this shut-<>ff requirement.
Maintenance of the shut-<>ff valve should only be undertaken if the valve is de-pressurized.
Ie pressure relief valves ES and ER are used to relieve the pressure of the connected contamination indicator, Pipes to the
Maintenance includes:
ntamination indicator and external test equipment can be fitted to connections S2 and R2.
- Exchange of replacement parts, item 1 to 7.
Tightening of the packing of the valve, item 1
In the case of a leak on the valve spindle of the valve, item 1, first tighten the packing. Only if this does not stop the leak
should the packing, item 6, and the annular bezel, item 5, or the whole valve, item 1 be replaced. The following torque
pressures must be observed when tightening the packing or exchanging the packing and annular bezel or valve.
Spindle nut SW14 10 to 20 Nm
Lock nut SW17 40Nm
Valve SW22 BONm
)624-4B
VOITM
14.8 Auxiliary lube oil pump
Auxiliary lube 011 pump - assembly

14.8.1 Gear pump
Type: R 69/315 FL-Z-W-R
14.8.2 Connecting coupling
Type: KC 080 A40A42-21
with rubber parts
14.8.3 Lantern (bell housing)
Type: Pt 350 A 160-212 SO
Operating instructions, Cover sheet ........ EL2-1500-351435-3; page 1
Spare parts list ........................ EL2-1500-351435-3; page 2
Operating Instructions ................................... L39-8W
Drawing, claw coupling .............................. 20500471310
134
Ersatzteile I Betriebshinweise
spare parts/pieces de rechangelparte di ricambiolpiezas de recambio
operating notes/ instructions de seNieel istruzioni d'eserciziol instrucciones de seNicio Fral03,09,98
Pumpenaggregat R69/500 ..630 FL-Z-W-R

pump unit/groupe moto-pompelgruppo di pompaggiolgrupo moto-bomba
Inhalt
content/indexlcontenutollndice
Ersatzteile (Schnittzeichnung) EL2-1500-351435-3

spare parts/pieces de rechangelparte di ricambiolpiezas de recambio
sectional drawmg/plan en coupeldisegno in sezione/plana en corte
8etriebshinweise fOr Zahnradpumpen L39-8W

operating notes on gear pumps/
instructions de seNice pour pompes Ii engrenages/
istruzioni d'esercizio per pompe ad ingranaggil
instrucciones de seNicio para bombas de engranajes
Rickrneier GmhH .W.rdohler PumpenfoDrik I .
Poslfud! 13 40· 0·58797 Bolve

longenhoithouser Sir. 20·22' 0-58802 Bolve
-----.,
;: .i .
RIC
' K ME'I E'R
. .
L-Te_iefc_n_o_23_7_S_/9_2_7-_0_T_ele_fox_O_2_3_7S_i_92_7_-2_6_____-.-_._ _ _ _ _ _ _ _ _ _ _ _ _....:1===,.=
... ,I WE R D 0 K l E RP U MP r_II',.\ B R i K J
Ersatzteile EL2-1500-351435-3
spare parts/pieces de rechange/parti di ricambiolpiezas de racambio
Fra/03.09.98
Pumpenaggregat R69/500...630 FL-Z-W-R

pump unit/groupe moto-pompelgruppo di pompaggiolgrupo moto-bomba
75
18
ill-----J-'7t---------I------r
3.0 2.0 1.2 t3 1.1 1.0
Pas. Menge Benennung

item/pos.l quantity/quantiteJ denomination!denomination!
pos.lpos. quantitBIcantidad denominazioneldenominecion
1.0 Zahnradpumpe kamplett

a
gear pump/pompe engrenages/
pompa aa ingranaggi/bomba de engrenajes
1.1 2 O-Ring
o-ring/bague oIe-ringlo-ring
Rechtslauf
1.2 Weliendichtring cw-rotation!rotation a
rotary shaft sealljoint dOetancheite dOarbrel droite/
anello di tenuta radiale sulralberolanillo de estanqueidad del eje rotazione destralrotaci6n a
derechas
1.3 4 Dichtring
sealing ring/bague dOetancheiteJ
ane/lo di tenuta/ani/to de empaquetadura
2.0 Klauenkupplung komplett

couplinglaccouplement/giuntolacoplamiento
3.0 Laterne (Pumpentrager)

bracketllanteme-supportl
/anterna del sopportellinterna soporte
Ridaneier GmbH· Werdohlar Pumpenfobrik

I'oSlfuch 13 40· D·58797 Bolve
IongenhoidlDUSBl SR. 20·22 •0-5B802 Bolve
Telefon 023 751927·0' Telefmc 023 75/9 27·26
Operating Notes L39-BW
on Edition 02197
Gear Pumps Sheet 1 (3)
1 General Signs directly provided on the pump, such as
1.1 Application - rotational direction arrow

- identification of fluid ports
RICKMEIER gear pumps are intended for
installation in a machine or for assembly with other must by all means be observed and maintained in
machinery. components to be assembled into a well legible state.
machine unit. Commissioning of the pump is 2.2 Qualification and Training of Personnel
prohibited until it has been proved beyond doubt
that the machine into which these gear pumps are to Personnel responsible for operation, maintenance,
be mounted or of which these gear pumps shall inspection and mounting must have adequate
form an integral part is in conformity with the qualifications to perform these activities. Areas of
applicable provisions of the EU Machinery responsibility, duties and supervision of personnel
Guidelines 89/392 EWG. must have been clearly defined by the Operator. In
6
the event that personnel lacks the necessary
Gear pumps must exclusively be used technical knowledge appropriate training and
. .for conveying lubricating liquids that do teaching must be initiated. Moreover, the Operator
neither attack the pump component must ensure that the contents of these operating
materials nor contain additives that notes has been cleac1y understood by the staff
promote wear. involved.
1.2 Operating Data 2.3 Dangers Associated with Disregarding these
The relevant data applicable to the individual Notes on Safety
operating conditions are specified in the framework Any failure to observe the safety instructions may
of an order, usually by means of job specifications, endanger not only personnel and machine but also
item-specific instructions, separate data sheets, the environment. Please note that claims for
drawings or similar documents. In the event that the damages may become forfeited if the safety
equipment operating conditions vary from what has instructions are not duly followed. In particular, a
been agreed before this must be clarified with and failure to observe these instructions may give rise to
agreed by the pump manufacturer, otherwise any the following dangerous situations:
warranty obligations will become VOid,
• Failure of important functions of the
2 Safety machine/plant
These operating notes contain basic requirements • Ineffectiveness of prescribed maintenance and
that must be met during mounting, operation and repair methods
maintenance. Therefore, it is mandatory that these
operating notes are carefully read by fitters as well • Hazards to personnel as a result of mechanical
as responsible personnel/Operator before mounting and chemical effects
and commissioning work is carried out. These • Environmental risks due to leakage of harmful
operating notes must always be at hand at the place substances
where the machine/plant is operated.
2.4 Working in a Safety-conscious Manner
Due attention must be paid not only to the general
notes on safety as described in this main safety The safety notes included in these operating
section but also to the specific safety instructions instructions, any applicable national regulations
preSCribed in other paragraphs. . governing accident prevention as well as any
in-house working, operating and safety instructions
2.1 Symbols Used in these Operating Notes issued by the Operator must be duly observed.
This danger sign identifies general 2.5 Safety Instructions for Operator/Staff
safety issues related to the protection
of personnel. • In case that hot or cold machinery parts create
danger these components must be safeguarded
by the Plant Owner to prevent accidental contact.
Notes intended to safeguard the gear
pump have been signified by this • In ~se of .pump types that have not been
symbol. provided with a coupling guard in the factory a
suitable safeguard has to be provided by the
Plant Operator.
RicKmeier GmbH· Werdohler Pumpenfobrik
=~~I~:~~rDS~8~&~2~OI~.S8802 8o~e 15.,.,,-,( I RIC K M E IE R

Telefon023 75/927.n· Telefux023 75/9 27.26 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~I.="=/='=":.-=W=E::R::O::O=:H::L::E=R=P=U+:M=P=lf~·=·F=A=8=R::::';~:....!!I
on Edition 02197
r----------------------------------------~------------------~------~~----~
• Touch guards meant to prevent contact with 4 Description
moving parts (eg coupling) must not be removed
from an operating pump. WP gear pumps are rotating displacement-type
pumps. When the input shaft is tuming the teeth of
• Any leakage (eg of the shaft seal) of hazardous drive gear and impeller engage in a reciprocating
media conveyed by the pump (eg of explosive, manner with the respective gaps in the mating gear.
toxiC, hot nature) must be disposed of in such a On the suction side the gap spaces created are filled
manner that no danger to persons or the environ with medium to be conveyed. On the delivery side
ment can occur. Any applicable legal provisions the medium is displaced by the teeth engaging with
have to be duly followed. the gap spaces.
2.6 Safety Instructions regarding Maintenance, The theoretical delivery rate is only achieved in
Inspection and Mounting Work pressure-less pump operating mode, iUs reduced by
the intemal losses as the pressure builds up in the
The Operator must take due care that all main system. The losses increase as the viscosity decrea
tenance, inspection and mounting work is ses but for the main part the losses are not related
exclusively performed by authorized and qualified to speed.
expert personnel that has informed itself sufficiently
by having studied these operating notes thoroughly. The basic pump design comprises the housing, the
drive and end covers as well as conveying gears.
Basically, all work carried out on the machine must Radially, the shafts are carried in plain bearing
be performed when the machine is at a standstill. sleeves lubricated by the medium to be conveyed.
Instructions included in these operating notes ~bout The drive shaft is normally sealed off by means of a
taking the pump out of service must by all means be radial shaft seal ring.
6
followed.
Loads acting on the shaft, eg from a gear
Pumps conveying liquids constituting a hazard to drive system, must not exceed the
health have to be decontaminated. specified admissible radial and axial load
All safety and protective systems must be replaced figures.
or made fully functionable again as soon as the In case of pumps provided with buitt-in pressure
work has been completed. relief valve care must be taken that this valve is
Before re-commissioning the system the remarks only allowed to have a pure safety valve function
given in Section 6 - Commissioning - must be care eliminating pump overpressure states. If this valve
fully read. is actuated the branched off output is led to the
suction side. In the event that the valve is expected
2.7 Pump Conversion and Use of Original Spare to be actuated for a prolonged time span a separate
Parts valve equipped with retum system connecting to the
A conversion of or modification to the gear pump is reservoir has to be employed, such as our RSn or
only permiSSible if agreed to by the manufacturer. DB9 models.
By the use of original spares and accessories Special design types and other pump variants may
approved by the manufacturer a satisfactory level of feature deviating technical details.
safety shall be warranted. If spare parts of other
makes are employed the liability for consequences 5 Mounting/Installation
ariSing from this may be denied.
Drive elements such as couplings and gearwheels
2.8 Inadmissible Operating Modes must be mounted onto the pump shaft providing for
an ISO H7 fit.
6
The operational safety of the gear pump supplied
can only be ensured if it is used as described under These components must not be driven
Section 1 - General - of these operating notes. The onto the shaft by hammering, othelWise
limiting values specified in the order must never be pump damage may occur.
exceeded.
3 Transportation and Intermediate The alignment between the pump shaft and driven
Storage machine must be carried out such that admissible
drive element - mismatch tolerances are not
The gear pumps are usually installed shortly after
exceeded and unnecessary forces prevented from
they have been delivered. Special measures to be
acting on the shaft.
taken for packing, preservation etc. must be
separately agreed upon.
Rid(llleier GmbH -Werdohler PIImpe"foblik'-~
lo"genholtho~ S~_ 20-22 . 0·58802 Bolve

Postfoch 1340-0-58797 Bolve
E,:,~,,; ~
_RICKM
" §Ji'IE-
-.,, R'
-_,.'.#_.'-
L-Tel_efo_"O_23_7_5/_9_27_0_T_ele_fax_O_23_75_1_91_7-_26____________________________ WE ROO H l E RP U;~P , fA B i I Kl
on Edition 02197
The pipewori< must be laid to avoid undue stresses. In the event of difficult suction conditions the pump
For the suction and delivery connections of pump should be mounted in such a manner that input
types with female threads only male components shaft and running axle are arranged one above the
with exactly fitting straight (cylindrical) thread must other. This mounting position will make sure that the
be employed. When connecting these elements residual oil volume remaining in the pump promotes
care must be taken to avoid impermissible stresses pump suction on re-starting. Alternatively, a pipe
from acting on the pump. siphoning arrangement can be provided.
The size of the pump suction connection does not There is always a residual amount of liquid in the
govern the cross sectional area of the piping. In gear pump. If a non-return valve has been
most cases a suction line cross section will be integrated into the suction line and/or if suction and
sufficient that matches the pump inlet cross section. delivery lines are arranged such that the gear pump
It is nevertheless recommendable to determine all cannot run dry all hollow spaces of the gear pump
elements of resistance in the system (gravity suction remain filled with liquid. Therefore, appropriate
head, pressure losses in the piping and across steps must be taken when dismantling the pump to
piping components - non-return valve etc.) to check collect this liquid.
whether there is a cavitation hazard.
Depending on the type of medium
~
The suction line must be absolutely tight. Any conveyed exiting liquids may endanger
unusual noise may be indicative of air being sucked , man and environment! For that reason
into the pump or of the pump operating in the cavi • effective steps must be taken in
tation range. conformity with the safety data sheets
of the respective liquids.
If suction fitters are used it must be made sure that
these filters are regularly serviced. It is recommend 7 Maintenance/Repair
able to monitor the pump inlet for negative pressure
to make sure the admissible pressure of -0.4 bar is Normally, the gear pumps do not require main
not exceeded as a result of filter fouling. The tenance.
pressure measuring point must be arranged directly When the pump is dismantled the housing parts
ahead of the pump inlet nozzle. must not be forced apart but should only be
All parts in contact with the medium to be conveyed separated by applying light blows with an elastic
must be carefully cleaned to prevent dirt from (rubber) hammer to housing and drive end cover.
entering the pump and cause damage or When reassembling the pump cleanliness (paint
destruction. Especially with hot-bent or welded remnants!) and correct seating of seals are of
piping systems care must be exercised to remove utmost Significance.
any remnants that may cause hazards. The shaft seal ring need only be replaced if leakage
6 ComissioningfTaking out of Service arises or if the input gear shaft has been renewed.
Running mar1<s on the shaft are not necessarily
Before the pump is taken into service it must be indicative of a defective sealing location.
checked whether the rotational direction of the
A bearing sleeve replacement is not recommend
driver matches the direction of pump rotation.
able. In case of a defective bearing the shafts and
6. During the check a pressure buildup

(eg due to a built-in non-return valve)
in the suction line must be aVOided,
otherwise the shaft seal may suffer
damage.
housing components usually have suffered damage
as well.
If a gear pump is worn out and cannot be used any
longer, it must be replaced. The installation of spare
parts cannot restore the pump's Original
For initial start-up and when again being perfonmance and service life. It is recommended to
commissioned the gear pump must be filled with the keep spare pumps on stock and return the
medium to be conveyed to wet the gears inside the dismantled pump to our Factory for repair.
pump.
For ordering purposes please indicate the required
If the pump is to deliver into a closed system it must technical details shown on the nameplate.
be vented on the delivery side during start-up.
Suitable venting arrangements have to be provided
in the delivery line. When operating two pumps in
parallel that are safeguarded against each other by
non-retum valves both pumps must be vented.
Mmeier GmbH· Werdohler Pumpenrobrik

Postloch 13 40· D·58797 Rolve
Longenhohhouser Sir. 1022 . 0·58801 Solve
Telefon 023 7S /927-0' Tolefox 0 23 75/927·26
RICKMI..ot...
11
WE ROO H L E R';p lJ p
Klauenkupplung-Einbauform JAW-TYPE COUPLING-ASSEMBLY FORM
Pumpenaggregat R69/200 ... 630 PUMP POWER UNIT R69/200 ... 630
98
3 18 3
I'///~ ~ ~:t\l
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Motorbaugroesse
MOTOR SIZE -------
1-- 1 - - - - - - R69/200
132 R69/250
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Benennung
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'~!i oj rek I~:" JAW-TYPE COUPLING-ASSEMBLY FORM
i ~1~~d,
Ze i chnungs-Nr _ / Doku-Nr. Bloll Sheet
W@O'O'DG 'O'QD~w@
Passmoss Abmosse
ANTRIEBSTECHNIK
Drawing No. I Doc. No.
20500471310 v.
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Dimension To I er antes ~rlpr . I ~rs. j I ~rs, \
VOITH
14.9 Three-phase motor for auxiliary lube oil pump
Type: M2 QA 160 M4 A
Rating: 11 kW
Voltage: 380 V
Frequency: 50 Hz, 3 phases
Speed: 1500 rpm
Degree of protection: IP55
Insulation class: F
Operating instructions .......................... Low-voltage motors
135
Low Voltage Motors
More languages - see web site

www.abb.com/motors&drives > Motors> Document library
Example of the Declaration of Conformity
given by ABB.
EC Declaration of Conformity
The Manufacturer : (Name and address of the manufacturer)
hereby declares that
The Products : (Product identification)
are in conformity with provisions of the following Council Directives:
Low Voltage Directive 73/23/EEC (amended by 93/68/EEC),
and, as components, with the essential requirements of the following:
EMC Directive 89/336/EEC (amended by 92/31!EEC and 93/68!EEC), regarding the intrinsic
characteristics to emission and immunity levels,
and are in conformity with:
EN 60034-1
Additional Information :
By design, the machines, considered as components, comply with the essential requirements of
Machinery Directive 98/37/EEC provided that the installation be correctly realised by the manufacturer
of the machinery (for example: in compliance with our Installation Instructions and EN 60204 "Electri
cal Equipment of Industrial Machines')
Certificate of Incorporation (Directive 98/37/EEC, Art 4.2 and Annex II, Sub B) :
The machines above must not be put into service until the machinery into which they have
been incorporated have been declared in conformity with the Machinery Directive.
Year of CE marking: CEOO.
Signed by ................................................ ..
Title .. ,......... ,............................................. .
Date ......................................................... .
Translations into other languages are availab!e from ASS.

Low Voltage Motors
Installation, operation and maintenance manual
Contents Page
1. General..................................................................... ............................................................ 4
1.1 Declaration of Conformity....................... ....................................... .............. 4
1.2 Validity.. ..... ....... ............... ...................... ......... ................ ... ........... ............................. 4
2. Installation ....................... .................................................................................................... 4
2.1 Putting into service (starting) ....................................................................................... 4
2.1.1 Reception check ........ ....... ................................ ....................... ........... ............. 4
2.1.2 Insulation resistance check.............................................................................. 4
2.1.3 Direct-on-line or star/delta starting................................................................... 5
2.1.4 Terminals and direction of rotation .... .................... ........... ........... ........... ......... 5
2.2 Handling. ........... ........... .... ....... ........... ............. ......... ...................... ........... .................. 5
2.2.1 Storage ............................................ .................. ................... ................ 5
2.2.2 Transportation................ .... .......... ....... ........ ....... ............... .... ....... .................... 5
2.2.3 Lifting .... ...... ............... .... ..... ................. ...... ....... ................... ............... ............ 5
2.2.4 Machine weights........................................................... ................................... 6
2.3 Installation... ....... .... ............. ................... ....... .... ........... ............. ......... ....... ............. ..... 6
2.3.1 Cooling................. .................. ................... ....................................................... 6
2.3.2 Foundation ....................................................................................................... 6
2.3.3 Alignment ......................................................................................................... 6
2.3.4 Slide rails and belt drives ................................................................................. 6
2.4 Connection ................................................................................................................... 7
2.4.1 Connection for variable speed drive ........ ....... ...................... ................... ........ 7
2.5 Balancing ..... ............................ ........................... ...... ........................... ......... .................. 7
3. Operating ............................................................................................................................. 8
3.1 Use ............................................................................................................................ 8
3.1.1 Operating conditions.... ..... .......... ................ ...... .................... ....... .................... 8
3.2 Safety considerations........ .... ....... ....... .................. ..... ... ........... ........ ...... ...... ............. ... 8
3.2.1 Points to observe.. ............. .................. .............. ................... .............. ............. 8
3.3 Assembly and dismantling .... ....... ............... .......... ........ ................. ............ ......... ......... 8
3.3.1 General..................................................... ........................................... .......... 8
3.3.2 Bearings.. ........................................... ......................................................... 8
3.3.3 Fitting coupling halves and pulleys.. .......................... ....... .......... ............ ......... 8
4. Maintenance ........................................................................................................................ 9
4.1 Maintenance and lubrication......................................... ............................................... 9
4.1.1 General inspection.... ....... ....................... ........... .......................... ...... .............. 9
4.1.2 Lubrication ..... ................................................................................................. 9
4.1.3 Machines with permanently greased bearings.. ......... .... ..................... 9
4.1.4 Motors with regreasing nipples... .... .................. ... .................. ........... ............. 9
4.1.5 Lubrication intervals and amounts ................................................................. 10
4.1.6 Lubricants ..................................................................................................... 10
4.1."7 Frequency converter drives ..................................................................... 11
4.1.8 Spare parts ............................. ..... .................................................... ... 11
4.1.9 Rewinding ....................................................................................................... 11
5. Environmental requirements ............................................................................................. 11
5.1 Noise levels .................................................................................................................. 11
6. Troubleshooting .................................................................................................................. 12
1. General 2. Installation
I NOTE! 2.1 Putting into service (starting)

These instructions must be fo!lowed to ensure safe
and proper installation, operation and maintenance of
the motor. They should be brought to the attention of
2.1.1 Reception check
~
i anyone who installs, operates or maintains this Immediately upon receipt check the machine for external
equipment. Ignoring the instruction may invalidate damage and if found, inform the forwarding agent
the warranty. without delay.
Check all rating plate data, especially voltage and
1.1 Declaration of Conformity winding connection (star or delta). The type of bearing is
Declarations of Conformity with respect to the Low specified on the rating plate of all motors except the
voltage Directive 73/23/EEC amended by Directive smallest frame sizes.
93/68 EEC are issued separately with individual Remove transport locking if employed.Turn shaft by
machines. hand to check free rotation.
The Declaration of Conformity also satisfies the

Do not exceed permissible loading values of bearings
requirements of a Declaration of Incorporation with

stated in the product catalogue.
respect to the Machinery Directive 98/37/EEC, Art 4.2

Annex II. sub B Motors equipped with roller bearings: Running the
motor with no radial force appiied to the shaft may
damage the roller bearing.
1.2 Validity
Motors equipped with angular contact bearing:
The instructions are valid for the following ABB

Running the motor with no axial force applied in the right
electrical machine types, in both motor and generator

direction to the shaft may damage the angular contact
operation.
bearing.
series Mr, MBr, MXMA,

Motors equipped with regreasing nipples:
series M2A*/M3A*, M2B*/M3B*, M2C*/M3C*,

When starting the motor for the first time, or after long
M2F'/M3F'. M2L*/M3L', M2M*/M3M*, M2Q',

storage of the motor, apply the specified quantity of
M2R*/M3W, M2V'/M3V"
grease until grease is forced out of the grease outlet.
in frame sizes 56 - 450.

For details see section "Manual lubrication" on page 9.
There is a separate manual for e.g. Ex motors 'Low

voltage motors for hazardous areas: Installation, 2.1.2 Insulation resistance check
operation and maintenance Manual' (Low Voltage
Motors/Manual for Ex-motors). Measure insulation resistance before commissioning
and when winding dampness is suspected.
Additional information is required for some machine
types due to special application and/or design Resistance, measured at 25°C, shall exceed the
considerations. Additional information is available for reference value, Le. 10M ohm (measured with 500 V de
the following motors: Megger)
_. roller table motors

... water-cooled motors
- open drip proof motors
- smoke venting motors
- brake motors
- permanent magnet motors Insulation resistance reference value is halved for each
20°C rise in ambient temperature.
If the reference resistance value is not attained, the
winding is too damp and must be oven dried.
Oven temperature should be gonc for 12-16 hours
followed by 105°C for 6-8 hours.
Drain hole plugs, if fitted, must be removed and closing
valve, if fitted, must be opened during heating.
2.2 Handling
Windings drenched in seawater normally need to be 2.2.1 Storage
rewound.
The machine should always be stored indoors, in dry,
vibration free and dust free conditions.
2.1.3 Direct-on-line or star/delta

Unprotected machined surfaces (shaft-ends and
starting flanges) should be protected with anti-corrosive
The terminal box on standard single speed machines

treatment.
normally contains 6 winding terminals and at least one
It is recommended that shafts be rotated periodically by
earth terminal.
hand to prevent grease migration.
Earthing must be carried out according to local
Anti condensation heaters, if fitted, should preferably be
regulations before the machine is connected to the
energised.
supply voltage.
The characteristics of electrolytic capacitors, if fitted to
The voltage and connection are stamped on the rating
single-phase motors, will require "reforming" following
plate.
periods of storage exceeding 1-2 years.
Direct-on-line starting (DOL):

Contact ABB Sales Office for details.
Y or D winding connections may be used.
e.g. 660 VY, 380 VD indicates V-connection for 660 V

2.2.2 Transportation
and D-connection for 380 V. Machines fitted with cylindrical-roller and/or angular
contact bearings must be fitted with locking devices
Star/Delta starting (Y/D):
during transport.
The supply voltage must be equal to the rated voltage
of the machine in D-connection.

2.2.3 Lifting
Remove all connection links from the terminal block.
Lift the motor using the lifting lugs only, if not otherwise
For two-speed, single phase and special machines,

stated in the separate lifting instruction.
supply connection must follow the instructions inside

The center of gravity of motors with the same frame
the terminal box.

may vary due to different outputs, mounting
If direct-an-line starting lasts for more than 10 seconds

arrangements and auxiliary equipment.
or Y/D starting more than 30 seconds, consult ABB

Check that eyebolts or the lifting lugs integrated with the
Saies Office or see the publication 'The Motor Guide'

moior frame are undamaged before lifting. Damaged
(also available on the internet on www.abb.com!

lifting lugs must not be used.
motors&drives).
Lifting eyebolts must be tightened before lifting.
If needed the position of the eyebolt must be adjusted
2.1.4 Terminals and direction of with suitable washers.
rotation
Ensure that proper lifting equipment is used and that
Direction of rotation is clockwise when viewing the shaft the sizes of the hooks are suitable for the lifting lugs.
face at the machine drive end, when the line phase

sequence L 1. L2, L3 is connected to the terminals as Care must be taken not to damage auxiliary equipment
and cables attached to the motor.
shown in the figure 1.

To alter the direction of rotation, interchange the
connection of any two line cables,
If the machine has a uni-directional fan, ensure that the
direction of rotation is according to the arrow marked on
the machine.
2.2.4 Machine weights Before mounting the motor, the foundation surface for
the shims or for the feet must be clean from thick paint,
Total machine weight can vary within the same frame paint drops and dirt. Then it should be checked in order
size (center height) depending on different output, to discover any height differences between the
mounting arrangements and added features. individual foot locations. Also, the smoothness within
The following table shows estimated maximum weights each footprint area has to be checked. The
for machines in their basic versions as a function of requirements are noted in the figure below,
frame material.
The actual weight of all our motors is stated on the Note! Height
Ruler difference shall not
rating plate except the smallest frame sizes.
exceed ± 0.1 mm
Aluminum ICast iron ! Steel referred to any other
motor foot location
Frame Weight Add. IWeight Weight
size kg for brake kg kg
56 4.5 - - -
63 6 - - -
71 8 5 13 -
80 12 8 20 - I
90 17 10 30 - L
100 25 16 40 - Foundation studs
112 36 20 50 - Bolt the foundation studs to the feet of the motor and
132 63 30 90 - place a 1-to-2 mm shim between the stud and the feet.
160 110 30 175 - Align the motor directly using appropriate means.
180 160 45 250 - Grout the studs with concrete, check alignment and drill
200 220 55 310 - holes for locating pins.
I 295
225 75 400 -
250 370 75 550 - Drain holes
280 405 - 800 600 Always check that open drain holes face downward.
315 - - 1700 1000

355 - - 2700 2200 In extremely dusty environments, all drain holes should
400 - - 3500 3000 be closed.
450 I - - 5000 I 4500

Table 1 2.3.3 Alignment
Correct alignment is essential to avoid bearing failures,
vibrations and possible fractured shaft extensions.
2.3 Installation
2.3.1 Cooling 2.3.4 Slide rails and belt drives
- Fasten the machine to the slide raiis as shown in
Normal ambient temperatures should not exceed 40°C
figure 2.
(marine standard +45 or +50°C) if standard
- Place the slide rails horizontally on the same level.
performance is to be achieved. Check that the motor
- Check that the machine shaft is parallel with driven,
has sufficient airflow. Ensure that no nearby equipment,
or driving, shaft.
surfaces or direct sunshine, radiate additional heat to
the motor. For more information about higher ambient - Any belt must be tensioned according to the
supplier's instructions.
temperatures and cooling, see "the Motor Guide" or
contact ABB Sales Office.
2.3.2 Foundation
The purchaser bears full responsibility for preparation of
the foundation. Do not exceed the maximum belt forces (i.e. radial
Metal foundations should be painted to avoid corrosion. bearing loading) stated in the relevant product
catalogues.
Foundations must be even, and sufficiently rigid to
withstand possible short circuit forces. They shall be
dimensioned as to avoid the occurrence of vibration due
to resonance.
2.4 Connection Potential equalisation
Normal machine design has the terminal box on top
with cable entry possible from both sides, Plate/strip Cables/wires
Some machines are available with top mounted terminal

boxes rotatable 4 x 90°, and some with side mounted
terminal boxes. 70 mrn
min 50 rnn/
Availability of these solutions is described in the product
catalogues.
Unused cable entries must be closed. To comply with EMC-requirements, use only cables and
connectors approved for this purpose, (See instruction
As well as main winding and earthing terminals, the
for frequency converters,)
terminal box can also contain connections for
thermistors, standstill heating elements, bimetallic, The highest permissible rotational speed of a cast iron
switches, or PT 100 resistance elements. motor used in variable speed drive (M2BA/M3BP) must
not exceed maximum permissible speeds as stated in
the table 2 below or the speed stamped on the rating
plate. For information on the highest permissible
rotational speed for other motor sizes and types, please
contact ABB. Bearing lubrication should follow the
directions mentioned later.
Connection diagrams for auxiliary elements are found Frame Speed r/min
inside the terminal box cover or in additional labels on size 2 pole 4 pole
the frame of the machine.
280 3600 2600
315 3600 2300
355 3600 2000
400 3600 1800
450 3600 1800
2.4.1 Connection for variable Table 2

speed drive
If there is uncertainty concerning the suitability of the
Variable speed drives cause higher voltage stresses
motor for the variable speed drive, please contact ABB.
than the sinusoidal supply on the winding of the motor
and may cause high frequency shaft voltages and
bearing currents. Therefore the winding and the bearing WARNING
insulation of the motor as well as the filter at the Try.~maximum
converter output must be dimensioned according to ~re.a.s~ and
"Selection rules for VSD applications/Insulation"

(3GZF500930-2), available on request from ABB. 2.5 Balancing
In variable speed drives the motor (Pn > 30 kW) must The rotor of the machine is dynamically balanced.
be cabled by using shielded symmetrical cables and
As standard, balancing has been carried out using half
cable glands providing 360 bonding (also called EMC
0
key, and the shaft is marked with a RED tape, with the
glands). More information can be found in ABB's
text "Balanced with half key". In case of motors
manual "Grounding and cabling of the drive system"
delivered without any tape defining the type of
(3AFY61201998),
balancing, these motors are also balanced with half
In frequency converter applications motor frame key.
external earthing must be used for equalising the
To avoid vibration the coupling-half or pulley must be
potential between the motor frame and the driven
balanced with half key after the keyway has been
machine, unless the two machines are mounted on the
machined.
same metallic base.
In the event of balancing with full key the shaft is
For motor frame sizes above IEC 280, use 0.75 x
70 mm flat conductor or at least two 50 mm 2 round marked with a YELLOW tape, with the text "Balanced
with full key",
conductors. The distance of the round conductors must
be at least 150 mm from each other. In case balancing without key, the shaft is marked
with a BLUE tape, with the text "Balanced without
This arrangement has no electrical safety function; the
key".
purpose is to equalise the potentials. When the motor
and the gearbox are mounted on a common steel
fundament, no potential equalisation is required.
3. Operating 3.3 Assembly and dismantling
3.1 Use 3.3.1 General

Dismantling and assembly of machines must be carried
3.1.1 Operating conditions out by qualified personnel using only suitable tools and
working methods. All repairs must be carried out
The madlines are Intended for use in industrial drive
according to the standard i EC-60079-19.
applications.
Normal ambient temperature limits are -20 0 to +40'C.
Maximum altitude 1000 m above sea level.
3.3.2 Bearings
Special care should be taken with the bearings.
These must be removed using pullers and fitted by
3.2 Safety considerations heating or using special tools for the purpose.
The machine is intended for installation and use by
How to replace bearings is described in detail in a
qualified personnel, familiar with relevant safety separate instruction leaflet available from ABB Sales
requirements. Office.
Safety equipment necessary for the prevention of
accidents at the installation and operating site must be 3.3.3 Fitting coupling halves and
provided in accordance with the local regulations.
pulleys
Coupling halves and pulleys must be fitted using
II motors· with supplycllJrenttllrectly suitable equipment and tools that do not damage the
switched by thermallysensit!v~,$yVjtctles bearings.
start automatically.
Never fit a coupling half or pulley by hammering into
3.2.1 Points to observe place or remove it using a lever pressed against the
body of the machine.
1. Do not use the machine to step on.
2. The temperature of the outer casing of tile Mounting accuracy of coupling half:
machine may be hot to tile touch during normal check that the clearance b is less than 0.05 mm and
operation. that the difference a1 to a2 is also less than 0.05 mm.
3. Some special machine applications require See figure 3.
special instructions (e.g. using frequency
converter supplies).
4. Lifting lugs must only be used for lifting the motor.
They must not be used to lift the motor when it is
attached to other equipment.
4. Maintenance Hours of operation for vertical motors are half of the
above values,
Motors with roller bearings have considerably shorter
4.1 Maintenance and lubrication grease life, For continuous operation regreasing nipples
should be considered,
4.1.1 General inspection
- Inspect the machine at regular intervals, 4.1.4 Motors with regreasing nipples
- Keep the machine clean and ensure free
ventilation airflow, Lubrication information plate and general
- Check the condition of shaft seals (e,g, V-ring) and lubrication advice
replace if necessary,
If the machine is fitted with a lubrication information
-- Check the condition of connections and mounting

plate, follow the given values.
and assembly bolts,

- Check the bearing condition by listening for On the lubrication information plate, regreasing intervals
unusual noise, vibration measurement, bearing with regard to mounting, ambient temperature and
temperature, inspection of spent grease or SPM speed of rotation can be defined.
bearing monitoring,
* When changes of condition occur, During the first start or after a bearing lubrication it may
dismantle the machine, check the parts appear a temporary temperature rise, appr, 10-20
and replace if necessary, hours, ABB policy is to have reliability as a vital issue in
bearing lubrication intervals, That is why we follow the
L 1-principle,
4.1.2 Lubrication
A. Manual lubrication
Regreasing while motor is running
- Remove grease outlet plug or open closing valve if
fitted,
- Be sure that the lubrication channel is open
- Press the specified amount of grease into the
bearing,
- Let the motor run 1-2 hours to ensure that all
excess grease is forced out of the bearing.
Close the grease outlet plug or closing valve if fitted,
4.1.3 Machines with permanently
Regreasing while motor is at a standstill
greased bearings Regrease motors while running, If this is not possible,
Bearings are usually permanently greased bearings of lubrication can be carried out while the machine is at a
either Z or 2Z types, standstill.
Bearing types are specified in the respective product - In this case, use only half the quantity of grease, then
catalogues and on the rating plate of all our motors run the motor for a few minutes at full speed,
- When the motor has stopped, press the rest of the
except smaller frame sizes,
specified amount of grease into the bearing.
As a guide, adequate lubrication for sizes up to 200 can - After 1-2 running hours close the grease outlet plug
be achieved for the following duration, according to L1 or closing valve if fitted.
(i.e, that 99 0;;, of the motors are sure to make the
interval time) at ambient temperature of 25°C, For B. Automatic lubrication
duties with ambient temperatures higher than 25°C, The grease outlet plug must be removed permanently
see the respective product catalogue, with automatic lubrication or open closing valve if fitted.
Some motors may be equipped with a collector for old
Frame size Poles Duty hours grease, Follow the special instructions given for the
56-80 2-8 for life equipment
90-112 2-8 40 000
2-8 We recommend only the use of electromechanical
132 40 000
systems, Contact your local ABB Sales Office.
160 2-8 40 000
180 2-8 40000 The amount of grease per each lubrication interval
200 2 27000 stated in the tables 4-5 should be doubled if an
200 4 40000 automatic regreasing system is used,
Table 3 If 2-pole motors are being automatically regreased, the

note (NOTE!) concerning lubricant recommendations
Depending on application and load conditions, see given for 2-pole motors in the chapter Lubricants shall
applicable product cataiogue, be followed,
4.1.5 Lubrication intervals and Factors influencing the lubrication intervals
Lubrication intervals for vertical machines are half of the
amounts
_. __
Frame
..... _._._._._
Amount 3600 3000 1800 1500 1000
"---"'
500-900
above values.
The lubrication interva!s are based on bearing operating
size of grease r!mm rimin r/min r/min r/min r!min temperature 80°C (ambient temperature of about
glbearing + 25°). Note! An increase in the ambient temperature
Ball bearings
raises the temperature of the bearings correspondingly.
Lubrication intervals in duty hours
The values should be halved for 15°C increase in
112 10 10000 13000 18000 21000 25000 28000
132 15 9000 11000 17000 19000 23000 26500 bearing temperature and may be doubled for 15 C G
160 25 7000 9500 14000 17000 21000 24000 decrease in bearing temperature.
180 30 6000 8000 13500 16000 20000 23000
200 40 4000 6000 11000 13000 17000 21000
225 50 3000 5000 10000 12500 16500 20000
250 60 2500 4000 9000 11500 15000 18000
280 70 2000'; 3500 1i 8000 10500 14000 17000
315 90 1) 'i 6500 8500 12500 16000
1j
355 120 1)
4200 6000 10000 13000
400 120 1i 4200 6000 10000 13000 4.1.6 Lubricants
400 M3BP 130 1)
2800 4600 8400 12000
450 140 2400 4000 8000 8800
Table 4
Roller bearings
Lubrication intervals in dut~ hours
160 25 3500 4500 7000 8500 10500 12000
180 30 3000 4000 7000 8000 10000 11500
200 40 2000 3000 5500 6500 8500 10500 When regreasing, use only special ball bearing grease
225 50 1500 2500 5000 6000 8000 10000 with the following properties:
250 60 1300 2200 4500 5700 7500 9000 - good quality grease with lithium complex soap and
280 70 1000" 2000 ' ) 4000 5300 7000 8500 with mineral- or PAO-oil
315 90 1)
3300 4300 6000 8000
355 120 ~ ) 1)
2000 3000 5000 6500 - base oil viscosity 100-160 cST at 40"C
400 120 1)
2000 3000 5000 6500 - consistency NLGI grade 1.5 - 3 *)
400 M3BP 130 1)
1400 2300 4200 6000 - temperature range -30'oC - + 120"C, continuously.
450 140 1200 2000 4000 4400
*) For vertical mounted motors or in hot conditions a
Table 5 stiffer end of scale is recommended.
1;Values for lEe sizes 280 to 450 (cast iron and steel molars) in certain
motor types (3600 and 3000 r!min), see tables 6-7. Grease with the correct properties is avaiiable from all
major lubricant manufacturers.
Lubrication intervals and amounts, 2-pole, Admixtures are recommended, but a written guarantee
lEe frame sizes 280 to 450 must be obtained from the lubricant manufacturer
Frame Amount 3600 3000 especially concerning EP admixtures, that admixtures
size of grease r/min r/min
g!bear;ng do not damage bearings or ttle properties of lubricants
Ball bearings at the operating temperature range.
Lubrication intervals in duty hours
280 M2B*. M2C*, M3B* 35 2000 3500
315 M2B'. M2C*, M3B' 35 2000 3500
355 M28* M2C* 45 1200 2000
355 M3S* 35 1200 2000
400 M2B*, M2C' 45 1200 2000
400 M3S* 40 1000 1600
450 M3B* 40 1000 1600
If the ambient temperature is below -25°C or above
Table 6 +55"C, or bearing temperature is above 11 ODC, consult
...... _--_ _ - - ...
Roller bearings
ABB Saies Office regarding suitable grease.
Lubrication intervals in duty hours_--:-=_ _
280 M2B*, M2C', M3S' 35 1000 1800 The following high performance grease can be used
315 M2S', M2C'. M3S* 35 1000 1800
355 M2B*, M2C' 45 600 1000 - Esso Unirex N2, N3 or S2 (lithium complex base)
355 M3B' 35 600 1000 - Mobil Mobilith SHC 100 (lithium complex base)
400 M2B', M2C' 45 600 1000 - Shell Albida EMS 2 (lithium complex base)
400 M3B' 40 500 800 - SKF LGHQ 3 (lithium complex base)
450 M3S' 40 500 800
- Kluber KlUberplex BEM 41-132
Table 7 (special lithium base)
- FAG Arcanol TEMP110 (lithium complex base)
Lubrication intervals for other grease fullfilling the
required properties, contact your local ABB Sales
Office.
NOTE! 5. Environmental
Always use high speed grease for high speed
machines and some other models, e,g. M2SA 355
requirements
and 400 2-pole machines, where the speed factor is
higher than 400 000 (calculated as Dm x n where 5.1 Noise levels
Dm = average bearing diameter, mm; n = rotational
speed, r/min). Most of our motors have a sound pressure level not
exceeding 82 dS(A) refer to 50 Hz sinusoidal supply
The following grease can be used:
conditions, tolerance ± 3 dS(A).
- FAG L69 (polyurea base)
Values for specific machines can be found in the

- KIOber Kluber quiet SH 72-102 (polyurea base)
relevant product catalogues.

- Lubcon Turmogrease PU703 (polyurea base)
For sound pressure levels for 60 Hz sinusoidal supply

If other lubricants are used, check with the
and with non-sinusoidal supplies, contact ASS Sales

manufacturer that the qualities correspond to those of
Office.
the above mentioned lubricants. or if the compatibility of
the lubricant is uncertain, contact your !ocal ASS Sales

Sound pressure !evels for all machines having separate
Office,
cooling systems and for series M2F*iM3F*, M2L *IM3L *,
M2R*/M3R', M2SJ/M3SJ and M2LJ/M3LJ are indicated
in separate Manua!s.
4.1.7 Frequency converter drives

Higher speed operation, e.g. in frequency converter
applications, or lower speed with heavy load will require
shorter lubrication intervals. Consult your local ASS
Sales Office in such cases.
Typically a doubling of speed will require a reduction of
lubrication intervals to approx, 40 % of values tabulated
above,
Suitability of bearings for high speed operation must be

checked.
4.1.8 Spare parts

When ordering spare parts, the full type designation
and product code, as stated on the rating plate, must be
specified.
If the machine is stamped with a serial manufacturing
number, this should also be given.
For more information, please visit our web site
www.abb.com/partsonline.
4.1.9 Rewinding
Rewinding should always be carried out by qualified
repair shops.
Smoke venting and other special motors should not be
rewound without first contacting ASS.
6. Troubleshooting
These instructions do not cover ali details or variations in equipment nor provide for every possible condition to be
met in connection with installation, operation or maintenance. Should additional information required, please
contact the nearest ABB Sales Office.
Motor troubleshooting chart
Your motor service and any troubleshooting must be handled by qualified persons with proper tools and equipment.
TROUBLE ICAUSE WHAT TO DO
Motor fails to start Blown fuses Replace fuses with proper type and rating.
------------------~--~----------~~--~--------~----~
Overload trips . Check and reset overload in starter. !
Improper power supply Check to see that power supplied agrees with
motor rating plate and load factor.
-----------------------------+--------~-------------------------~
Improper line connections Check connections with diagram supplied with
motor.
Open circuit in winding or control Indicated by humming sound when switch is
switch closed. Check for loose wiring connections.
Also, ensure that all control contacts are closed.
Mechanical failure Check to see if motor and drive turn freely.
Check bearings and lubrication.
. Short circuited stator Indicated by blown fuses. Motor must be I
Poor stator coil connection rewound. Remove end bells, locate with test I
lamp.
f-----------------------j---'------------------·---------..J
Rotor defective Look for broken bars or end rings.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application r Change type or size. Consult manufacturer. I
Overload Reduce load. I
Low voltage I Ensure the rating plate voltage is maintained.
Check connection.
Open circuit Fuses blown, check overload relay, stator and
push buttons.
Motor runs and then Power failure Check for loose connections to Ine. to fuses and I
I
idles down to control.
f-M-o-t-o-r-d-o-e-s-n-o-t-c-o-m-e-u'-p+-N-o-t-a-p-p-lie--d--p-ro-p-e~I~;---------- -- Consult suppli~r for proper type. - - - !
to speed Voltage too low at motor terminals Use higher voltage or transformer terminals
because of line drop or reduce load. Check connections. Check
conductors for proper size.
Starting load too high Check load motor is supposed to carry at start.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may !
Ibe required, as repairs are usually temporary. I
~. . . ______ ?pen prima~y._?!!?~i!.
_________ j Locate fault witht~stingdevice and repair. l!
I Motor takes too long to Excessive load Reduce load. I
accelerate and/or draws Low voltage during start Check for high resistance. Adequate wire size.
high amp
Defective squirrel cage rotor Replace with new rotor.

Applied voltage too low Get power company to increase power tap.
Wrong rotation Wrong sequence of phases Reverse connections at motor or at switchboard.
TROUBLE CAUSE WHAT TO DO

! !
Motor overheats while Overload
;--.. -_.._.
Reduce load. ..... _-_ .. _--_. .._._
running underloaded Frame or bracket vents may be Open vent holes and check for a continuous
clogged with dirt and prevent proper stream of air from the motor.
ventilation of motor
Motor may have one phase open Check to make sure that allleaas are well
connected.
Grounded coil
Locate and repair.
~otor
Unbalanced terminal voltage
Check for faulty leads, connections and
transformers.
vibrates Motor misaligned

Realign.
Weak support
Strengthen base.
I
Coupling out of balance
Balance coupling.
Driven equipment unbalanced

Rebalance driven equipment.
Defective bearings
Replace bearings.
Bearings not in line

Line up properly.
Balancing weights shifted

Rebalance motor.
! Contradiction between balancing of Rebalance coupling or motor.
rotor and coupling (half key - full key)

Polyphase motor running single Check for open circuit.
phase
I Excessive end play Adjust bearing or add shim.
Scraping noise
Fan rubbing fan cover Remove interference.
Fan striking insulation Clear fan.
! Motor loo~e on bedplate Tighten holding bolts.
Noisy operation
Airgap not uniform Check and correct bracket fits or bearing.
Rotor unbalance . Rebalance.
-
Hot bearings ball
Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension,
Pulleys too far away Move pulley closer to motor bearing.
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of drive.
---
Insufficient grease Maintain proper quality of grease in bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly
contaminated
in kerosene and replace with new grease.
Excess lubricant
Reduce quantity of grease, bearing should not
be more than 1/2 filled,
Overloaded bearing
Check alignment, side and end thrust
Broken ball or rough races

Replace bearing, first clean housing thoroughly.
L1 PE l1 L2 L3
~ (Dt~~-I
it-O I I
I() () OJ
L.uJ.. . S L'lLLJ
L3 L2
Figure 1. Connection diagram

Bild 1. AnschluBdiagram
Figure 1. Connection
Figura 1. Conexi6n
Figura 1. Coliegamento
Figur 1. Anslutningdiagramm
Kuva 1. Kytkentakaavio
\;.-.-------:1
I \
Figure 2. Belt drive

Biid 2. Riementrieb
Figure 2. Glissieres et entrainements a courroie
Figure 2. Carriles tensores y correas
Figura 2. Slitte tendicinghia e pu!egge
Figur 2. Remdrift
Kuva 2. Hihnakf3ytt6
Figure 3. Mounting of half-coupling or pulley
Bild 3. Anbau von Kupplungshalften und Riemenscheiben
Figure 3. Montage des demi-accouplements et des poulies
Figura 3. Montaje de mitades de acoplamiento y poleas
Figura 3. Montaggio di semigiunti e pulegge
Figur 3. Montering av kopplinshalvor och drivskivor
Kuva 3. Kytkinpuolikkaan ja hihnapybran asennus
Low Voltage Motors
Manufacturing sites (*) and some of the biggest sales companies.
8o
Australia
France
Korea
Switzerland o
N
ABB Industrf Ply Ltd
ABB Aulomation
ABB Korea ltd,
ABB Schweiz AG
2 Douglas Street
Port Melbourne,
Rue du General de Gaulle
Champagne-sur-Seine
7-9fl, Oksan Bldg" 157-33
Sungsung-dong, Kangnarn-ku
NormeloclCMC Components
Motors&Drives
~
N
Victoria, 3207
FR-77811 Morel-sur-Lolng Cedex
Seoul
Badenerslrasse 790
Tol: +61 (0) 3 9644 4100

Tel: +33 (0)1 60746500
Tel: +8225282329
Postfach
Fax: +61 (0) 3 9646 9362

Fax: .33 (0) 1 60746565
Fax: +82 2 528 2338
CH-8048 Zurich
Tel: +41 (0) 58 586 0000
Austria
Germany
Malaysia
Fax: +41 (0) 58 586 0603
ABBAG
ASS Automation Products GmbH
ABS Malaysia Sdn Blld,
Wienorborgstrasse 11 B
Edisons! rasse 15
Lot 608, Jalan SS 1311 K
Taiwan
AT-181 0 Wien
DE-68623 Larnpertheim
47500 Subang Jaya, Sclangor
ABB Ltd
Tel: +43 (0) 1 601 090

Tel: +49 (0) 6206 503 503
Tel: +60 3 5628 4888
6F, No. 126, Nanking East Road,
Fax: +43 (0) 1 601 09 8305

Fax: +49 (0) 6206 503 600
Fax: +60 ~l 5631 2926
Section 4i
Taipei, 105 Taiwan, RQ,C.
Belgium
Hong Kong
Mexico
Tel: +886 (0) 2 2577 6090
Asea Brown Boveri S.A,-N,V,

ABS (Hong Kong) Ltd,
ABB Mexico, SA de C.v
Fax: +886 (0) 2 2577 9467
Hoge Wei 27
Ta i Po Induslna! Estate,
Apartado Postal 111
SE-1930 Zaventern
3 Dal Hel Streel,
CP 54000 Tlalnepartla
Thailand
Tel: +32 (0) 2 7186311

Tai Po, New Territories,
Edo, de Mexico, Mexico
ABS Limited (Thailand)
Fax: +32 '(0) 2 7186657

Hong Kong
Tel: +52 5 328 1400
161/1 SG Tower,
Tel: +852 2929 3838

Fax: +52 5 3903720
Soi Mal1adlekluang 3,
Canada
Fax +85229293505
RaJdamn Bangkok 10330
ABS Inc" BA Eleclrical Machines

The Netherlands
Tel: +662665 1000
10300 Henri-Bourassa Blvd, West,

India'
ABBBV
Fax: +662 665 1042
Saint-laurent, Quebec
ASS ltd.
Dept. LV motors (APP2R)
Canada H4S 1Nt

32, Industrial Area, N,I.T
PO,Box 301
The United Kingdom
Tel: +1514832-6583
Faridal:lad 121 OOt
NL-3000 f\H Ro1terdam
ABS Automation Ltd
Fax +1 514332-0609
Tel: +91 (0) 1295023001
Tel: +31 (0) 104078879
9 The Towers, Wilmslow Road
Fax: +91 (0) 129 502 3006

Fax: +31 (0) 104078345
Didsbury
China'
Manchester, M202AB
ABB Shanghai Motors

Indonesia
Norway
Tel: +44 10) 161 4455555
Company Limited
PT. ABB Sakti Industri
ABBAS
Fax: +44 (0) 1614481016
8 Guang Xing Rd"Rong Bei

JL Gajah Tunggal Krn, 1
P,Q,Box 154 Vollebekk
Town, SongJiang County,

Jatiuwung, Tangerang 15136
NQ-0520 Oslo
USA
Shangnai201613
Banlen, Indonesia
Te!: +47 22 872 000
ASS Inc.
Tel: +86 21 5778 0888

Tel + 62 21 5909955
Fax: +4722872541
Low Voltage Motors
Fax: +8621 5778 1364

Fax: + 62 21 5900115 - 6
16250 W, Glendale Drive
Singapore
New Berlin, WI 53151
Chile
Ireland
ASB Industry Pte Ltd
Tel: + 1 262 785 3200
Asea Brown Boveri SA

Asea Brown Boveri ltd
2 Ayer Rajah Crescent
Fax: + 1 262 785 8628
P,Q,Box 581-3
Componenls DIVision
Singapore 139935
Santiago
Belgard Road
Toi: +65 6776 5711
Venezuela
Tel: +56 (0) 2 5447 100

Tallaght. Dublin 24
Fax: +6567780222
Asea Brown Bover! S,A,
Fax: +56 (0) 2 5447405

Tel: +353 (0) 1 4057300
P,Q,Sox 6649
Fax: ,353 (0) 1 405 7327

Spain'
Carme'itas,
Denmark
ABS Automation Products S,A,
Caracas 1010A
ABSNS
Italy'
Division Motores
Tel: +58 (0) 2 238 2422
Automation Technology Electrical

ABB SACE SpA
p.o.sox 81
Fax: +58 (0) 2 239 6383
Machines
LV Molars
ES-08200 Sabadell
Petersmlndevej 1
Via Della Meecanica, 22
Tel: +34 93 728 8500
DK-5000 Qdense C
IT-20040 Caponago - MI
Fax: ·,,34 937288741
Tel: +4565477 070

Tel: +39 02 959 6671
Fax: +4565 477 713

Fax: +39 02 959 667216
Sweden'
ABB Automation Technologies AB
Finland'
Japan
LV Molars
ABS Oy
ABB K.K,
SE-721 70 VAsteras
LV Motors
26-' Cerulean Tower
Tei: +46 (0) 21 329000
P.O.Box 633
Sakura98oka-chO, Shrbuya-ku
Fax: +46 (0) 21 329 140
-...
FI-65101 Vaasa
Tokyo 150·8512
Tel: +358 (0) 1022 11

Tel +81 (0) 3 578 46251
Fax: +358 (0) 10 22 47372

Fax: +81 (0) 3 578 46260
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VOITH
14.10 Heat exchanger
14.10.1 Working oil heat exchanger:
Voith Article No.:

Type: not supplied by Voith-Crailsheim
14.10.2 Lube oil heat exchanger:
Voith Article No.:
Type: not supplied by Voith-Crailsheim
Assembly Plan
Working oil .............................................. __
Lube oil ................................................ .
Installation and operating instructions .......................... __
iii
:I:
."
EO
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..:
c
0
.~
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co
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c;;
ci
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Cl
c:
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~ 136
VOITM
14.11 Shutoff valve - Oil reservoir
Voith Article No.:
Type:_
Description .............................................. __
137
VOITN
14.12 Vent filter - Geared variable speed coupling
Type: TLFI 3-40 G 25 .... SO
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. EPE-10
iii
J:
-cE!
";;
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c
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~I
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~ 138
Breather Filters
TLF I..., TLF II...,TLF III...,
Industrial Filters . Accumukkors
BF...,BE...,EF...,EFK..
Filters for tank mounting
Efficient filtration of air
Air breather filters wHh

changeable spin-on filters
(BF and BE)
Combined air breather and filler
filters (TLF, EF, EFK, FEF, FES, BE)
Flange mounted filters
Low pressure drop
Special high efficient filter media,

a/so for water absorbing
.....
a.&all
.....
• • • • 111
.....
.....
.....
II • • • •
• • • BII
::u=
Breather Filters mil Performance Characteristics
II::: Air flow characteristics
m~~
Test tempemture. 20°C
TLFO", TLF", BF", BF5. .., BFV.. TLF.... 1·25 TLF. 2·32 ... TLF... 3-40 TLF. .. 4-50
.
IT
EF .., EFK .., FEF .. I I
II VT~ •
/
BS 7SL..., BE 7SL..., B 7SL...
f- I
Operating temperature : --" 5

/'
-loDe to + lOoDe II II 3
' / I ","I
I
]'// IJ viI
Application
-y
I
1
I
ll:
2
,
I
l- ~7
T
i
Filtration and dehumidifying of intake air for

1
, 2 3 5 10 Xl 30
1
10 20
3CI 50 100
LuftdurchSirb:(m3/h) LuftdllrcJUiu{mYh)
industrial systems. lII:::

il!1 TLF.... 565 TLF..- 680
In::
::::: ,. I .~ I
/ v:
'" I
V 11
Design :::::
f
TLF. ..: filter housing for breathing and ventilation ::=== ~---'fi
with changeable filter element inside. Filter lEU!

..... I
/ 7
II
elements H. ..5L up to 7pm filtration grade with V II

V lYl
glass-fibre filter media, water absorbing filter
media AS optional Types: I with female thread or 5Eii;
Illlt , j
II
k II t,f f
DIN flange (for size TLF 18-20), II with male .....

II:::
10 20 38 50 100
llifttiurchsan( m3/h)
200 300
I
10 2O.'JO 50
luftdurdSllt%{1I13/h)
100 200 300
thread, III with male thread (with flange for size

B ••••
TLF.... 7125 ..
TLf.. 8250
TLF III 7-725) and filler filter (730 pm strainel).

mil
20
I t I/:
I
1/ Vtl
Type TLF 0 with 500 J.lm synthetic strainer. .....
:1::: iE
10
- r--'
Illil I•
I
SF, BFS, BFV...: compact housing for breathing , : j"

'I
and ventilation with integrated filter media (BF) :1:::
I
i ,
I'
/ '1 I
II
i
or pleated filter element made out of paper ( BFS,
BFV). Design with a dip stick possible. i~m

=:::: 1
10
Y lil~I
20 3(l 60 100 ZIO 300 500
I
1000
1
500
lY U"i
101lC1 2000 3QOO
I
5000
Bypass valves 0,7 bar for in and outflowing oil' lllhrlurdtsatz (m~/~ l
200 "'"
LlIftdUlc.hsatz (m3/h)
for type BFV mil '"

...
BF. 8 32 BFS7 BF520
iii::
.....
• • 11 • •
~.,/ ~! I~V I ~ III
EF. ..: 730 pm filler strainer with screwed on :::!!

..... ~
I
10
breather cap and interior sintered bronze plate. 55i55 7" , ~

,
I
I~
I /1
I
/ "'II ')1 I 1 7
EFK. .. : 730 pm filler strainer with screwed cap, ~ /

/ J 1
3
/1
without breather. 7
..... V / Ill'
, I / I T
,
~llii
1
1
1 2 :; ~ 10 2 3 5 10
FEF..: combination out ofa flangeable filler filter luftdu~hWltzlm3/h) Lllftdurchsa1:l{m3/h)
( 500 pm strainer) and a breather cap including .....

.BIIII.
FEFO FEFI
a 40pm foamed material .....
B ••••
===== 1/1:1 /
..... • -~
II • • • •
The breather cap can be removed through a I::::
bayonet joint and is secured with a chain. I::::
j
E i
::::5 1
• f:~~J.+j
"
55!!! I
SF 75L...:, SS 7 SL...: breather filter with a spin
on filter and pleated filter element with filter
:1::: I 3
I
111
II
'TII
paper P Design with flange connection (BF 7

SL) or female thread (BS TSL .J
lil!t , ,
2. 1 S
I
10 2Q
iiili
lvftdurch~tz(ml/h)
BF. 857 SL 45/21 SF 857 SL 90

.....
..... '"
B 7SL..., BE 7SL...: design as SF... and BS 7 SL,
however with connection for maintenance -' •
I
0 .L t-
~-
if
indicator (B 7 SL.) and /or extension with a
filler filter (500 pm strainer).
!i!!1 ]j
•j , 5
0:.'77
nm ! , ~
I
'/
I
, '<c'/I
/.f
I
Materials: as per spare parts/ist in this brochure. IUii 3
mi~ , IYI
10 15:;.>0
f
2530
,20
If
30
,
50 70
I
100
LuftdurchsslZ (mJ/h) ~uftdurchsatz( m3/h)
iii!! 20
I
8F. 85 7SL130 BE B TSL 45121
t/"
!~nl •
vV1
•
I
: ~
.....
:1:::
- j
•s
.....
:::==
.....
I
• • • I!!fi
1;~5i II
/
I , i ..--j
)
~
5i!!! I/.<f , Vii
I::::
•••a.
n:::
===::
.oV I Jfr I
I
I
.....
••a••
1
'" :Xl
l~hduldlsatl
~
(m3/h I
70 100 10 15
Luftdurch>atJ: (mJ/~ )
20 25 30
iiiii
Ordering Filter Type Magnet Maintenance Indicator Connection Material

TLF., = reservoir breather a= without a=withaut 00.= standard 0. = standard
'\ Information
,f TLF 0
filter, flange mountable
reser/OJ( breather
Selection of filter size. filter, flIJr 1 qe mountable
using the computer program with filler sUO/ner
TLF I reservoir breather

nEPE - FlLTERSELECT nor filter H,ith female
thread, abbr. DIN
performance characteristics connectlOr;

in this brochure. TLF 11, .. = reservoir b.. euther I
hlter with male threaa' I
connectlQii I ,
Special designs TLF /1/ = reservoir breathe!
filter wit muir; thread I
available on request. connect/or., abbr. DIN I i
~--
flange and filler stramer
~-----.JI ~------.J
I I-~
I I
Filter Assembly -.... TLF III 7 - 725 -- - S
-PlO 00 o o o 00 P 0 0
--
I- -
T T
Seal Kit *
, I
~DTLFIII
I
7 - 725
;c

1 T i-r l -
T
00 P Q
T
Nominal Size
I
Filtration Grade Differential i Filter Element Design Bypass Valve Seal I Additional
Pressure Information
0 . =standard adhesive I 0= Without
TLFI.II. III l-L5 T' C
nominal filtration grade In
" 2·32 1 0=
2-3) TLFO C = stainless steel wire cleanable

Maximum T = 80 C D without 0= without
C 10 C25 G40 C60 GSO C 100
3-40 allowahle P= 5 =silicon free
TLF I, ill 7-725 VS = nonwoven media, not cleunable
4-50
V525 V540 V560 pressure drop BunaN E = vent valve
Z = inspection
I
5-65 p= paper, not cleanable across the
680
!iF I 8250 filter element
I
P5 PIO P25 I certificate J
Filter- Filter Element Size absolute filtration grade (IS04572)in ).1m
I
S =standard
Element No/!,I(!GI Elem[li! i;lmJenl H. ..5L = micro glass-fl·bre, not cleanable
,\'GIIJJ~C
5 = silicon free
;'" SOle 51u Size
H ISL H3SL H65L HIOSL
Type. ;-25 002 '~ 680 006 ... 0 =standard material C = silicagel
H20SL
~
2-32
AS= micro glc5s·fibre, watef ...2 = Zinc free , Z = inspection
3·40 7-725 007 , certificate
7 absorbing, not cleonable
4-50 004 I
8-250 oosl ASI AS3 A56 AS 10 AS20 I
I HS I
I
I I II I i
I I I-~
Filter Element -.... 7. 00 Q
Dimensions
TLF 02-32 TLF 2-32 TLF 17-125 TLF 18-250
----.<'
r----"'-'""'-7"------,
f'-~~4
I co
L ~~~---F=d~
! ,
FlonschA1Z5){/1 I>
139.7DrN2573 ~ 2W :c+-J....o...---""'4"i...L--<
"
~--. -!l
/~.,
. l1J~~.:..
-I ---,..
\ I::v
Spare Parts
Size TLF 2-32 I TLF 2-32 I TLF2-32 I TLF 2-32
Weight il1 kg 0.,5 I 0,6 I 8,0 I 33,0
Part Qty. Designation IMaterial
7
7 Cover I Steel please indicate ordering information "Filter Assembly"
I
2
7 Wing nut Steel Part No. 4349 I Part No. 5233
3
7 Filter Element Various please indicate ordering information "Filter Element" I
4 7 Filter hOUSing I Various please indicate ordering informatIOn "F:lter Assembly"

,
) 6 7
1------
Filler strainer I Various
~-
- I Part No. 5767 I Part No.5 784 I
7 7 Seal I Runa N please Indicate ordering II1formation ''Seol Kit"
8 7 Seal I BunaN please indicate ordering InformatIOn "Seol Kit"

'Seal Kit only for TLF/TLF 0 2-32, TLF 1///1 7-725 and TLF I 8-250
8'11111 • •
......
1I!1:I1I!IIiI
III • • • •
•••Il.
• iI • • •
lIatll ••
1111 •••
• 11111 • •
~,l
Dimensions TLF I... TLF II...
.....
II
11\1--+-3
TLF III...
Design with filler nozzle

and filler stramer
:t: -, 1-'--_
, _-;
I~
iA+-+-3
~t J..L._ _ _ _ ;<;=="l--~
Design with filler nozzle
Size Weight A B C D E F C H J K SW
II in kg
TLF I 7-25 1 0,5 C7 53
0702 24 e92 43
TLF12-32 0,6 63
TLF 13-40 2,1
TLfl4-50 2,1 0777 46 , 0762 C2 98 88
TLFI565 7,6 1 02 1.2
1---0-=--3-=--+--8-::-:8:--l ---78
TU16-80 i 1,9 e210 45 o 790
5EiSE TLFII125 0,6

13 702 l1 77 ~~0~7_~~5~3~,i, 43 I 6
45
TLF112-32 0,7 o i i." 63 55

I TLFII3-40 2,3 07 i 2 60
r r:-::;-
1
TLFII 4--5::CCc-·--+--2CC-,-c-
3 --i e 777 762 7 75
46 i g
I- - 78
-1--'--
98 88
TLF1I5-65 2,0 20 02 112 8 90
TLF116-80 2,3 e270 45 {j 790 I 22 C3 78 78 9 705
TLFII17-25 0,7 /J 702 24 13 92 {j 27 707 17 C7 53 43 I 6 46
TL FIll 2-32 0,8 {j 36 723 C 7'/~ 63 I -55
I-----T-L-FI-II-3--4-0--+--i,s I e42 747 78 C 71/2 ! 7 60
TLFII14-50 2,5 e 777 46 {j 162 1352,5 177 C2 98 88 I 75
-----::-----1--:-:---1
~I__TLFII_I5::--6-::-5c_ - - i _::--,3-::---+--::-::-::----1----:-::_-t----:-::--::--+-{j_6:::-;7:--+--::-20-,-,9::--t--__=_:::_
2 20--cl-0 =-2=-'Il~_-:-::---'-_____c=-=--__+-8=---t--9-0--l
I TUIII 6_80__----'-_2_,7_--'--_13_2_1O---'_4_5__ILo_19_0_ _0_8_2_-'--_24_6_-'----_2_2_+-_C_3_ _ _78_--'--_78_--'--_9_--'-----'-'1O~5---'
Spare parts
Size TLF I, TLF II, TLF III
Part Qty DesignatIOn I Material I 125 I 2-32 1
3 -40 I 4-50 I 5-65 i
6 - 80 I
1 1 Cover i Steel please indicate ordering information "Filter Assembly"
2 1 Wing nut Steel i Part No. 4349 I
3 7 Filter element Various I
please indicate ordering information "Filter Element"
--
I 4 7 Filter housing Various please indicate ordering infcrmatlon "Fi!ter Assembly"
m!! 5 7 I Filler nozzle Aluminium IPert No. 3650 Part No. 36581 Part No. 3659 I Part No. 3660 I Parr No. 3667 I Part No. 3662
6 7 filler strainer Various I Part No. 365i , Part No. 3663 I Part No. 3664 I Part No. 3665 I Part No. 3666 I Part No. 3667
Ii Filler nozzle and filler strainer only available as Unit

Seal kit IS not possible
Ordering
Information
J
Selection of filter size: Filter Assembly -.- BF 75 5730 F o o
uSing the computer program
T I I T T T
"EPE· FlLTERSELECT" or
performance ci1aractcmtlcs
in th.is brochure.
Spwal designs
aVa/labie on request
Seal Kit .. 0 T__ 5130

-----r- I
F
I
o
Nominal Size Filtration Grade Seal Matenol

= Breather filter 8,75,20,25,32 5130 O=standard
BFV = Breather with 5 ~ silicon free
20 5730
I B pass Valve Q = dip stick BF, EF
I BFS = Breather with

7 and EFKanly
P5 P70 P25
I Filter Element 20 F = Fibre (standard)
Z = Inspection
IFEF = Breather and o
570 S20 S40 certificate
Filler Filter 1
• EF = Breather and U5 0= without

~Filter 2-32
~I
3-40
4-50
I EFK ~ Filler Flltel

5-65
6-80
L - -_p=B_unaN----..J
Dimensions
Size I Weight In kg A B C D E F .
C SW NW
!
BF 8 0,05 55 10 20 030 9 55 C' .) 19 9
8F15 0,7 705 I
25 e50 12 105 C 1/2 27 I 13
?2
BF20 0,15 140 26 13 140 C 3/4 35 i 18
e 60 I
BF25 0,2 775 27 75 175 CI 47 23
76
BF32 0,3 225 35 e80 77 225 C 1'/4 55 32
,
BFS 7 0,03 , 77 41 e46 6 C '/4 79 , 7 I
BF520 - 57 1387 75 -_..

BFV 20
0,3 72
54 e77 14
C 314 32 I 78
I i
EFI I 36 e60 ,
0,4 107 77 a28 C7 46 25

ErK 7 37 i
038
f- , ,
I EF2 39 77 e 67
0,5 737 e34 C 7i 55 32
I EF!: 2 40 ,I 79 047
I
EF3 ..
44 i8 075
-----
0,7 155 e42 G i'.-2 60 40
----
UK 3 47 19 054
- f
EF4 .--J 0,8 187

48 78 093
e53
I
I
I
02 75 50
EFK 4 I 46 22 066 I
I
i EF S 58 20 0720
1,4 218 067 e2'12 90 6S
EFKS I -
57 24 1383
EF6 69 22 e 740
7,6 2S6 0B2 03 70S 80
EFK6 SS 26 e96
FEFO 0,77 62 48 0S0 e4S 1328
- -
FEFI 0,23 98 54 e83 e 76 049
Spare Parts
I Size
BF832
BFS 7, BFS 20
EF II EFK I EF21 EFK2 EF 31 EFK 3 EF41 EFK41 EF51 EFK51 EF6 i EFK61 FEFO FEF 7 I
! BFV20
Part I Qty. Designation Matenal Part No.
7 7 Cover :, Various please indicate ordering information "Filter Assembly"
2 i 7 Flange Steel please indicate ordering information "Filter Assembly"
3 I I
I Filler nozzle Aluminium I 3650 3658 f 3659 3660 I 3661 3662 I

I 4 I I Filler strainer Vartous

-
3651 3663 3664 3665 I 3666 3667 157791 5767
5 I 7 i
~- i~ ~-~-~- ~
Filter plate sika-B 200
- I
I 6 I Locking ring Spring steel 5647 ; 5642 - 5643 5644 5645 5646 I
I
7 3 Oval head screw 4.8 15783 1 - I
, -
8 6 Socket head cop SCtel-V 4.8 [
1 - I 5770 [
--
9 i Seal BunaN
_70_7 I Seal Fibre
,
please indicate orderinO InformatIOn "Seal Kit"
17 I ) Seal Fibre i
c. - ----- I
Filler /10ZZ12 and filler ,trcuner only available as unit

Dimensions
BF 8-32 BF5 7... /BF5 20... BFV 20
0 D
-.- !
10
'-' V u V
UJI
OJ
,_G~_
EF 1-6 EFK 1-6 FEF 0 and FEF 1
SW
D=SW
r
1 2
"'L i -9 11
r- I ;->-'
uL I
1
NW
---3 4
I
I G1
I I
i I
I I
I
I
i
I
I I
E hole pattern FEF 0 hole pattern FEF 7
lockable design on request
Quality and Standardisation

The development, manufacturing and assembly of EPE Industrial filters and filter elements is performed within
the guidelines of a certified quality management system according to DIN EN 1509007.
The calculation ofstrength and the filter tests are done in compliance to actual pressure vessel regulations and
national & international standards.
A filter inspection by accredited certification bodies
(e.g. TtJV, CL, LRS, LRIS, ABS, BV, DNV, DRIRE, UDT etc.) is possible on request.
.....
.....
I!!ii
11111
Ordering Filter Type Magnet Maintenance Indicator I Connection I Materia~ iiiE!
BF 75L : Breather Filter 0: without 0= without I00= standard o= standard
55!!!
Information
~im
I
with flange A= pressure gauge M 070
Selection of filter size: B5 75L: Breather with
using the computer progran7

welded hexagon
nipple
only for B TSL and BE 7SL
IConnectioll
B 7 SL and
for
"EPE ~ FlLTERSELECT" or For technical data see aur i BE TSL = with

[dedmpP!'
BE 7 SL : Breather with
performance charactenstics I FIller Filter brochure "Maintenance Indicotor"
in this brochure I B 75L = Breather wIthout I
Special designs
Fi'ler Filte' :
avwlable on request.
I I
I I
, I I I I
Filter Assembly -.. SF 7SL 90 PIO - 5 00
-, o o A 00 P o o
-I T TI T T
Seal Kit >- D BF 7 SL ~
Filtration Grade

-1
Differential I Filter Element DeSign
I A
I
Bypass Valve Seal
p
T
Q
I
Additional
:::::
.....
::==:
iEEii
iiiii
nomina! filuatlon grade in pm Pressure 0",: standard adhesive 0 = without p; Information :===:
\/5"" nOmvOIlErl
IIS25 V540
medw, not cleanable
11560
Maximum
allowable
I
I T = 1000e BunaN 0= without
5 = silicon free
.....
iEEE!
=====
P= paper, not cleanable
P5 PIO P25 pressure drop
oaosHhe
E... =spec/OI adhesive
T = 160'e
E = vent valve
Z = inspection
!iiii
I
absolute filtration grade (/504572) in pl71 filter element certlftcate
H.. 5L = micro g/oSS·r,·bIE, not cfeanable
.H IS! H3S! ,~6SL H 10.11
H20SL
5: standard
AS = micro gloss·fibrE, water
5 = silicon free
absorbing, not cleanable
p
AS I AS] AS6 AS 10 /,.\20
0= stal1dord matertall-rl L_---r_---1 _Z_=_in-,s_e_c_tl
certificate
_'O_I1..J
I
1 iiiii
55!!!
I I i I
S Q E
lim
II • • • •
BE 7 SL 45/21, B 7 SL 45/21 BS 7 SL 45/27,

BS 7 SL 90 and 730
BF 7 SL 45/21,
BF 7 SL 90 and 130
!iiii
jf::::J1J[
<Q .,-0-
r-~'~~~
D
Ilili
II • • • •
=====
1
:-1
}-tl
; --+--.....
,_....l - Manometer
~~~~ MOIO G
(0 ~ 6 bar)
I \
i '
c
,--H-
Dimensions
I 0 E
I Size Weight A B C F
G H
I in kg I
I!
fliil
ii!ll!
I BF TSL 45/21 0,8 I 191 I 146 iJ60. e92 7 G% I
'BF7SL90 1,4 229 783 085 i e 728 10 GI~1
I BF 7 SL 730 1,5 277 237 e85 iJ 727 10 GI~I
BS 75L 65/21 0,7 191 r 146 035 092 G% I
I B5 7SL90 1,3 229 183 iJ50 el28 GI~
i BS TSL 730 7,4 277 231 fi 50 I gl27 GI%I

I BE TSL 45/21 1,3 68 146 085 092 10 98 Gil g 49
iiEE:
G1 I
~i!ij
1B 7SL45/21 1,2 ~
73 ~~_I4.~J 060 g92 16 036
Spare Parts
,
iiiE!
:::::
BF TSL 45/21, BF TSL 90 and 130 I BE TSL 45/21
I,
_ I_ ,
- ~-,
SIZe BS 7 SL45/21, BS TSL 90 and 130
Bs TSL 45/27
illii
il555
Part Qty Designation Matenal I
,~--- ---_.-
·-11 7 5prn~onfiiter Various please fI1dlcote ordering information "5pin On Fiitel'
2 I Seal BunaN l Part No. 5767
~L~ 5uO/ner PA 6 please indicate ordering information "5ea! Kit"

I 4 I Seal BunaN please Indicate ordering information "Sea! Kit'
1 5 I Flat /-lead Screw 4,8 I Part No. 4285
aEiii
••• ~-=
:1:::
••• 1111
Dlra ••
:::::
:::::
• • •!!III
:=::: Installation, Starting and Maintenance
lEPEr
:::::
ii555
.....
II:::
iim Filter Installation
Industrial Filters' Accumulators :::n
•••11. Flange filter assembly at mounting device or in reservoir opening.
lE:!!
5i::: Starting
iU::
55!5: Switch on system pump and start system. Pay attention to flow noise
I::::
II::: at breather filter If flow noise can be heard, check size selection in
iii!! accordance to air flow rate (Initial flow resistance < 20 mbar).
II:::
• • • &11
.....
EiUi Maintenance
m~1
.....
• • • 11 •
•••• 11
BE, B75L45/21 .. 'If a vacuum or overpressure of 0,02 bar is displayed,
the spin on filter 80.45/21 needs to be replaced.

All other breather filters do not have any maintenance indicators.
iUii
II::: We therdore recommend to check or to replace breather filters in
!iiii
I::::
regularly periods according to following table.
II:::
~~
filter application environmental service interval
conditions
average dust )
ES!!; concentration
EiiSE 9 ·25 mg/m3 4000h
general mechanical
iim engineering I
55!!! :heavy industry 50 - 80 mg/m3 3000h
=====
ie!E! r-;;;.;-,:;
.81i8 •
• • • IiI~
mobile hydtaullcs 30 100 mg/m 3 3000h
• • • • 1lI
II!II
mil Filter Element Service
TLF:
E5!EE
• • D••
I:::: open cover (Part /) by unscrewing wing nut (Part 2) .
• • • • .Ii
I::::
• • • EI&
Replace (H..5L, Pand Vs..) or clean (G. .. materiai) filter element in the
• • • ElIi!
case of visual contamination.

Insert filter element (Part 4) in filter hous!l7g and refit cover while
IIIII tighten wing nut hand screwed
mil
:::::
BF, B5, BE, B 7St.. .
unscrew spin-on filter (Part 1) and refit new one with seal (Part 2)
.....
nIl:
• • BIIII
...I::::
tli:: .,.
hand screwed.
n~5E BF 8·32, BF5, BFV.. :

unscrew filter, replace completely and screw on again uSing a new
iiill
ii::i
fibre seal (Part 10).
EF ..
mn unscrew cover (Part 1)and replace filter disc (Part 5).
iiill
a••••
EFK ..
unscrew cover (Part 7) and check strainer (Part 4) for contamll1ation,
mil clean if necessary, check seal (Part 9) for damage and refit cover.
.....
ii!!:
~~m FEF.. :
open cover (Part 7) , release from security chain and replace, close
security chain.
II
Check filler filters during maintenance for contamination
K & H. Eppensteiner GmbH & Co. KG
and clean if necessary
l-IardtwaldstraBe 43 . 0·68775 Ketsch/Rh.
Postfach 77 20 . 0·68768 Ketsch/Rh.
Telefan: 06202 / 603·0
Telefax: 06202 / 603·199 iiaii
E-Mail: Eppensteiner@compuserve.com
Internet: www.Eppensteiner.de iiii~ Technical modifications reserved I 70/07 / 70.99/6000
1111I
YOITM
14.13 Measuring connection· Geared variable speed coupling
Measuring tubing
Type: SMA 3-800
Pressure gauge connection
Type: MAV 1/2 - MA3
Measuring connection
Type: EMA 3 R1/4
Drawing ......................................... 3626-010430
139
Measuring Connection Type EMA3 with Screw Connection M16
Example of Application
Pressure
Identification Color (Supplied upon receipt
of Screw Connection of an order)
Yellow
e connection
Measuri hose
Typ SMA 3/SMS 20
Length BOOmm
Screw cap
IZeichnungs-Nr.: 3.623 - 10430 e I

1 )18244;airev-Ger
VOITH
Voith Turbo I Geared variable speed coupling I SEC S6 Indonesia Pelabuhan I R 15 K 400 M
Table of contents
Appendix_A_
Preservation method and instructions for storage after delivery 3625-006714
140
Ib 137 PC
Preservation methods and storage instructions after
VOITM
delivery for coupling types R, RW, S, MOe and
torque converters, as well as for assemblies
This regulation contains an overview of preservation methods, storage and inspections of machines and assemblies after delivery, as well
as general instructions.
packed for sea

transport acc. to unpacked
~
3625-006212, acc. to 3625
preserved for 12 or 006212,
24 months preserved for
6 months
.I
:1
unpacked L J
max.3 x I
J
J.
~ installation I
preserved
acc. to 3625-006212
I I
see 1.
point 4 for 12 or
24 months ~
~ ~
I in air-conditioned
hall see 1.1
II in non-air-condi-
tioned hall see 1.2
II in the open
see 1.3
I
~ ~ ~
S t 0
.r a g e I n s t a I I a t i 0
. n
see 2. System installed, not in operation or at standstill> 24 hrs see 3.
in air-conditioned in non-air in the open in hall with constant in hall with varying in the open
storage room, reI. conditioned air temperature air temperature
humidity < 40% storage room
see 2.1 see 2.2 see 2.3 see 3.1 see 3.2 see 3.3
Replacing:
3625-006714, 2004-06-01
2008-01-16; airee-TRg Voith Turbo GmbH & Co. KG - 0-74555 Crailsheim - Postfach 1555· 3625-006714en
airev - KHi Tel. +497951 32-0· Fax 32-500 Rev. 1 Page 1/13
Preservation methods and storage insructions after
VOITN delivery for coupling types R, RW, S, MDe and

General
Voith units and their assemblies are high quality investment goods whose perfect condition is to be
preserved during installation and assembly work, long periods of storage and after installation or in
cases of standstill for operational reasons. The measures necessary during these phases and the
necessary inspections are described in the following. The work carried out is to be documented.
When carried out carefully, the storage and preservation procedures described are suitable for
maintaining the perfect condition of the deliveries in the period between dispatch from Voith
Crailsheim and commissioning.
In addition to protection of the external corrodible surfaces by applying film forming, water
displacing anticorrosive agents, the measures described are based on the creation of a dry, or
alternatively a dry and oxygen-free climate in the interior of the units. The aim is to achieve and
maintain relative air humidity in the interior =< 40%, as below this air humidity no corrosion occurs.
The following can be used to create the dry climate in the interior of the units:
- sorption air dehumidifiers
- dry compressed air
- technical nitrogen with a sufficiently low dew point
Assemblies, such as gear stages, are to be treated as exposed external iron parts and are
generally to be stored packed in accordance with Voith no. 3625-006212 points 2 - 4 or in air
conditioned rooms, unless agreed otherwise, or delivered in special containers for long-term
storage.
1. Installation of Voith units in a system: general instructions:

Special attention is to be paid to the efficacy of the preservation, as it is frequently subject
to additional dangers due to water, severe dirt accumulation and mechanical damage.
During installation, maintenance of the efficacy of the preservation is to be checked
regularly and documented.
- Installation is to be carried out preferably in buildings but at least under a roof or tent
providing protection against weather conditions.
- For assembly purposes, cleaned exposed external iron surfaces are to be sprayed on the
same day with a film forming anticorrosive agent, e.g. Shell Ensis Fluid S, or to be painted.
- Do not unpack cold units (below dew point) in warm rooms but only after temperature
equalisation.
Attention: When installing in rooms, do not use nitrogen for protection against corrosion due to
toxic hazard!
2008-01-16 3625-006714en
airee-TRg Voith Turbo GmbH & Co. KG - 0-74555 Crallsheim Rev. 1
airev-KHi Postfach 1555 . Tel. (07951) 32-0 . Fax 32-500
Page 2/13

1.1 Installation of a Voith unit in a system in an air-conditioned hall
See also point 1.
The following measures apply to an air-conditioned hall which is defined as follows:

- Temperature range 18 to 26°C
- Relative air humidity within the range 35 to 65 %
- Low airflow
- Temperature fluctuation within 24 hrs < 8°C
If one of the conditions stated is not met, the measures according to point 1.2 for "Non-air
conditioned hall" are to be applied.
Spray exposed iron parts with a film forming, water displacing anticorrosive agent, e.g.
Shell Ensis Fluid S. (Clean surfaces of the units sprayed with preserving agents with a
suitable cleaning agent, white spirit or paraffin before fitting or mounting parts, e.g.
tightening hubs). After fitting or mounting parts, re-coat remaining exposed iron surfaces
with anticorrosive agent, spray or coat with paint.
To protect the interiors of the units against corrosion during installation, the following
methods are recommended:
a) Dehumidification of the air in the interior of the units with sorption air humidifier.*
- Provided no covers, flanges etc. of the units are opened, the air in the interior of the
machine is to be dried every 3 days with a sorption air dehumidifier. Permissible
relative residual humidity =< 20%. The ventilation filter is to be sealed with a plastic
film.
- After opening the housing by removing covers, flanges etc., the interior of the unit is to
be dried immediately with a sorption air dehumidifier. *
Unscrewed covers, flanges etc. are to be refitted as quickly as possible, at least after
% hour, or replaced by provisional covers, to reduce the penetration of humidity to an
unavoidable minimum.
The permanent supply of the interior of the unit with dehumidified air via a sorption air
dehumidifier is permitted. It is recommended to control the unit with a hygrostat. The
relative air humidity in the interior of the machine should be =< 40%.
b) Supply of the interior of the unit with dry compressed air. Volume flow approx. 5 to 10
Ilmin (sufficient for up to 6m3 volume of the interior). The atmospheric dew point of the
compressed air must be below -5°C.
- Provided no covers, flanges etc. of the unit are opened, the interior of the machine is
to be filled after with dry compressed air every 3 days. The purging process is to be
carried out with at least 5 times the volume of the interior.
- After opening covers, flanges etc., the interior of the unit is to be flowed through
immediately with dry compressed air.
* see page 12
"
"0
~
2008-01-16 3625-006714en
.c
E airee-TRg Voith Turbo GmbH & Co. KG - 0-74555 Crailsheim Rev. 1
'"~ airev-KHi Postfach 1555 . Tel. (07951) 32-0 . Fax 32-500
u Page 3/13
VOITM delivery for coupling types R, RW, S, MDe and

Unscrewed covers, flanges etc. are to be refitted as quickly as possible, at least after
% hour, or replaced by provisional covers, to reduce the penetration of humidity to an
unavoidable minimum.
The permanent supply of the interior of the unit with dry compressed air is permitted. The
atmospheric dew point of the compressed air must be below -5°C.
1.2 Installation of a Voith unit in a system in non-air-conditioned hall
See also point 1.
The following measures apply to a non-air-conditioned hall which is defined as follows:

- Moderate airflow
If one of the conditions stated is not met, the measures according to point 1.3 for "In the
open" are to be applied.
a) Dehumidification of the air in the interior of the units with sorption air humidifier.*
machine is to be dried every 3 days with a sorption air dehumidifier. Permissible
relative residual humidity =< 15%. The ventilation filter is to be sealed with a plastic
film.
be dried immediately with a sorption air dehumidifier. *
Unscrewed covers, flanges etc. are to be replaced by provisional covers immediately to
reduce the penetration of humidity to an unavoidable minimum.
The permanent supply of the interior of the unit with dehumidified air via a sorption air
relative air humidity in the interior of the machine should be =< 40%.
b) Supply of the interior of the unit with dry compressed air. Volume flow approx. 10 to
15 Ilmin (sufficient for up to 6m 3 volume of the interior). The atmospheric dew point of
the compressed air must be below -10°C.
*see page 12
machine is to be dried every 3 days with a sorption air dehumidifier. The ventilation
2008-01-16 3625-006714en
airee-TRg Voith Turbo GmbH & Co. KG - 0-74555 Crailsheim Rev. 1
airev-KHi Postfach 15 55 . Tel. (07951) 32-0 . Fax 32-500
Page 4/13

filter is to be sealed with a plastic film. The purging process is to be carried out with at
least 5 times the volume of the interior.
be dried immediately with dry compressed air.
Unscrewed covers, flanges etc. are to be replaced by provisional covers immediately to
Permanent supply of the interiors of the unit with dry compressed air is permitted (10
15 I/min). The atmospheric dew point of the compressed air must be below -10°C.
1.3 Installation of a Voith unit in a system in the open
See also point 1.
Installation of the units and work during which covers, flanges etc. are unscrewed, are to be
carried out under a roof or in a tent.
a) - permanent supply of the interiors of the units with dehumidified air with
sorption air dehumidifier.*

- Unscrewed covers, flanges etc. are to be replaced by provisional covers immediately to
b) - permanent supply of the interiors of the machines with dry compressed air.
Atmospheric dew point of the compressed air =< - 40°C.
Volume flow approx. 10-15 Ilmin (sufficient for up to 6m 3 volume of the interior)
- Unscrewed covers, flanges etc. are to be replaced by provisional covers immediately to
c) - permanent supply of the interiors of the machines with technical nitrogen, volume flow
approx. 10- 15 I/min. (sufficient for up to 6 m3 volume of the interior), required
pressure approx. 0.002 bar. Dew point of nitrogen =< -70°C.
Attention: All works on the unit must be performed under special safety measures
when using nitrogen.
Toxic hazardl
* see page 12
~
~ 2008-01-16 3625-006714en
"'E" airee-TRg Voith Turbo GmbH & Co. KG - 0-74555 Crailsheim
Rev. 1
'"ut! airev-KHi Postfach 15 55 . Tel. (07951) 32-0 . Fax 32-500
Page 5/13

2. Storage. general instructions
Requirements for the storage of Voith units or systems in closed rooms:
• The storage room should be dry, with low dust levels, moderately ventilated and free of
vibrations.
• The basic condition for storage is that no aggressive media, such as gases, vapours or
aerosols of acids, alkaline solutions or salts can act upon the machines.
• Ensure sufficient stability, also on inclined surfaces.
• Packed machines must only be stacked or placed on top of one another in such a way that
the air circulation is maintained.
• All machines must be easily accessible for inspection and maintenance work for:
- reading off moisture indicators
- inspection of the machines
- repairs to packaging
• Do not unpack cold machines (below dew point) in warm rooms, but only after temperature
equalisation.
• Filling or permanent supply of machines with nitrogen is not permitted in rooms due to toxic
hazard.
For storage of assemblies, see page 2, "General"
Requirements for storage in the open:
• Unpacked machines may only be stored in the open if they are intended for outside
installation.
• The storage temperature should be within the range 0 to 40°C.

• The storage area must be free of vibrations. It should preferably have a sturdy foundation,
e.g. concrete slab, it must at least be safe against flooding and fixed in such a way that the
machines and components do not sink into the mud even during long periods of rain. The
formation of puddles and stagnant water are to be avoided. Machines are to be placed on
squared timbers.
• Direct sunlight is to be avoided, as apart from the damaging effect of the ultra-violet
radiation, it leads to great temperature fluctuations.
• Tarpaulins are to be secured against gale-force winds. It must be ensured that no rain can
accumulate and that air circulation is possible under the tarpaulins.
• The condition of the tarpaulins and packaging is to be inspected regularly for damage due
to weather conditions, rotting and being eaten by animals. Defects are to be remedied
immediately.
For storage of assemblies, see page 2, "General" .
"0
S:! 2008-01-16 3625-006714en
.c
E., airee-TRg Voith Turbo GmbH & Co. KG - 0-74555 Crailsheim Rev. 1
!:! airev-KHi Postfach 1555· Tel. (07951) 32-0· Fax 32-500
Page 6/13
'"'

2.1 Storage in air-conditioned storage room
See also 2.
The following measures apply to an air-conditioned hall which is defined as follows:
- Relative air humidity < 40%
- Low airflow
Adherence to the storage conditions is to be checked regularly and documented.
unpacked units
The following measures are to be carried out during the period of storage:
- spray external exposed iron parts at least every 2 years with a film forming, water
displacing anticorrosive agent, e.g. Shell Ensis Fluid S. (Clean sprayed surfaces with
white spirit or paraffin before installing the machines).
- turn the shafts of roller bearing units at least every 2 years by approx. a quarter to a half
turn in order to prevent standstill marks (false brinelling) in the roller bearings.
- spray interior surfaces every 2 years with solvent-free anticorrosive agent, e.g. Shell Ensis
engine oil 20.
Storage in packing according to Voith no. 3626-006212 points 2 to 4 is permitted.
2.2 Storage in a non-air-conditioned storage room
See also 2.
The following regulation applies to a non-air-conditioned storage room which is defined as

follows:
- Moderate airflow
If one of the conditions stated is not met, the regulations according to point 2.3 for "Storage
in the open" are to be applied.
The following methods can be used to protect the units against corrosion:
a) - Packing in accordance with Voith no. 3625-006212 point 4. It is recommended to check
the efficacy of the drying agent regularly with moisture indicators, see table page 11
- the condition of the packaging is to be checked regularly for damage. Defects are to be
remedied immediately.
- the aluminium compound foil is to be replaced after 2 years. (Aluminium compound foil
is not UV-proof).
The efficacy of the preservation of the exposed iron parts is to be checked.
If necessary, the preservation is to be touched up with a film forming, water displacing
anticorrosive agent, e.g. Shell Ensis Fluid S.
~
~
2008-01-16 3625-006714en
..c
S airee-TRg Voith Turbo GmbH & Co. KG • 0·74555 Crailsheim Rev. 1
'"
~ airev-KHi Postfach 1555 . Tel. (07951) 32-0 . Fax 32-500
u Page 7/13

- turn the shafts of roller bearing units at least every 2 years by approx. a quarter to a
half turn in order to prevent standstill marks (false brinelling) in the roller bearings.
b) Unpacked units
permanent supply of the interior of the unit with sorption air dehumidifier. *
- at least after 1 year check external parts for efficacy of the preservation,
if necessary preserve exposed iron parts again with a film forming, water displacing
Permanent supply of the interior of the units with dry compressed air may be used as
alternative to the sorption air dehumidifier. Volume flow approx. 10 to 15 I/min (sufficient for
up to 6m 3 volume of the interior). The atmospheric dew point of the compressed air must
be below -10°C.
2.3 Storage in the open
See also 2.
The following methods can be used to protect the units against corrosion:
a) Packaging in accordance with Voith no. 3625-006212 point 4. It is recommended to
check the efficacy of the drying agent regularly with moisture indicators, see table page
11
- after at least 1 year, the exposed external iron parts are to be checked for efficacy of
the preservation. If necessary, the preservation is to be restored with Shell Ensis Fluid
S. (Clean sprayed surfaces with white spirit or paraffin before installing the machines)
- the aluminium compound foil is to be replaced after 2 years (Aluminium compound foil
is not UV-proof).
b) unpacked units:
- provide rain protection (roofing, tent, tarpaulin etc.)
- spray exposed iron parts with a film forming, water displacing
For preservation of the interior of the units, the following procedures can be used:
- permanent supply of the interior of the machine with a sorption air dehumidifier.*
- permanent supply of the interior of the machine with technical nitrogen, approx. 10
15 I/min (sufficient for up to 6 m3 volume of the interior), required pressure approx.
0.002 bar. Dew point of the nitrogen =< -70°C
* see page 12
"
"C
S::! 2008-01-16 3625-006714en
..c
E airee-TRg Voith Turbo GmbH & Co. KG - 0-74555 Crailsheim
on
Rev. 1
~ airev-KHi Postfach 1555 . Tel. (07951) 32-0 . Fax 32-500
u Page 8/13
VOITM delivery for coupling types R, RW, S, MOe and

- permanent supply of the interior of the unit with dry compressed air.
Atmospheric dew point of the compressed air =< - 70°C.
Volume flow approx. 10-15 Ilmin (sufficient for up to 6m3 volume of the interior)
3. Mounted systems installed on the foundation; not yet in operation or at standstill
Special attention is to be paid to the efficacy of the preservation, as it is frequently subject

to additional dangers due to water, severe dirt accumulation and mechanical damage.
Spray exposed external iron parts with film forming, water displacing anticorrosive agent,
e.g. Shell Ensis Fluid S. Grease and move functional parts, e.g. joints, monthly.
Fill systems with operating oil wherever possible, please refer to operating manual.
3.1 The following measures apply to systems installed on the foundation in hall with constant
temperature
See also point 3.
The following methods can be used to protect the interiors of the units against corrosion:
a) Operable systems
Start up system at least every 3 months and operate it briefly (approx. 5 minutes) for oil
moistening of the internal parts and surfaces.
b) Non-operable systems
- With operable electrical start-up lubrication pump, this is to be put into operation every
3 months for approx. 5 minutes. (Do not run up to hot condition!)
- With a non-operable electrical start-up lubrication pump, remove oil from the sump
every 3 months, spray through housing openings in the interior and circulate oil by
pumping with separate oil pump through pipelines for approx. 5 minutes. Race system
where possible.
c) Alternatively the following methods of internal anticorrosive protection can be used,

especially for non-oil-filled systems:
- dry air in the interior of the unit monthly. The permissible relative air humidity should be
= < 40 % at the lowest expected ambient temperature.
d) Supply of the interior of the unit with dry compressed air. Volume flow approx.
10 to 15 Ilmin (sufficient for up to 6m3 volume of the interior). The atmospheric dew point
of the compressed air must below O°C.
* see page 12
"
"0
S! 2008-01-16 3625-006714en
.J:l
E airee-TRg Voith Turbo GmbH & Co. KG - 0-74555 Crailsheim Rev. 1
'"~
(.) airev-KHi Postfach 1555 . Tel. (07951) 32-0 . Fax 32-500 Page 9/13
VOITN delivery for coupling types R, RW, S, MOe and

3.2 The following measures apply to systems installed on the foundation in a hall with slightly
varying air temperature
See also point 3.
a) Operable systems
Start up at least every 2 months and operate briefly ( approx. 5 minutes) for oil
moistening of the internal parts and surfaces.
b) Non-operable systems
- With operable electrical start-up lubrication pump, this is to be put into operation every
2 months for approx. 5 minutes. (Do not run up to hot condition!)
- With a non-operable electrical start-up lubrication pump, remove oil from the sump
every 2 months, spray through housing openings in the interior and circulate oil by
pumping with separate oil pump through pipelines for approx. 5 minutes. Race system
where possible.
c) Alternatively the following methods of internal anticorrosive protection can be used,

especially for non-oil-filled systems:
- dry air in the interior of the unit monthly. The permissible relative air humidity should be
=< 40 % at the lowest expected ambient temperature. If this is not possible in one
pass through the sorption dehumidifier due to the climatic conditions. the air must be
dehumidified in a closed circuit.
In case of extensive temperature variations and/or high air humidity, measures d) or e)

(optionally) are required in addition.
d) The permanent supply of the interior of the unit with dehumidified air via a sorption air
dehumidifier is permitted. *
e) Supply of the interior of the unit with dry compressed air. Volume flow approx.
10 to 15 I/min (sufficient for up to 6m 3 volume of the interior). The atmospheric dew point
of the compressed air must be below -10°C.
3.3 The following measures apply to systems installed in the open on the foundation
See also point 3.
a) The permanent supply of the interior of the unit with dehumidified air via a sorption air
relative air humidity in the interior of the machine must be =< 40%.
* see page 12
2008-01-16 3625-006714en
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VOITN delivery for coupling types R, RW, S, Moe and

b) Supply of the interior of the unit with dry compressed air. Volume flow approx.
10 to 15 Ilmin (sufficient for up to 6m 3 volume of the interior). The atmospheric dew
point of the compressed air must be below -40°C.
c) permanent supply of the interiors of the machines with technical nitrogen, volume flow
approx. 10 - 15 I/min. (sufficient for up to 6 m3 volume of the interior), required
pressure approx. 0.002 bar. Dew point of nitrogen =< -70°C.
Attention: All works on the unit must be performed under special safety measures
when using nitrogen.
Toxic hazard!
With operable electrical start-up lubrication pump, this is to be put into operation every 3 months
for approx. 5 minutes.
Table for inspection intervals of humidity indicators to TL 6685 ..
Display value of the Inspection intervals

humidity indicators
Blue eve!), 8 weeks
30 % pink every 2 weeks
40 % pink Weekly
50 % pink Correctly restore preservation
-8
N
2008-01-16 3625-006714en
.r>
i., airee-TRg Voith Turbo GmbH & Co. KG - 0-74555 Crailsheim
Rev. 1
t! Postfach 15 55 . Tel. (07951) 32-0 . Fax 32-500
<> airev-KHi Page 11/13
* Anticorrosive protection with dehumidified air is based on the fact that no corrosion occurs below
a relative air humidity of 40%. The relative air humidity depends on the temperature.
Permissible residual humidity is to be determined in accordance with the lowest expected ambient
temperature. At this temperature it should be =< 40 %.
The relative permissible air humidity at which the air in the interior of the units is to be dried is
determined with the aid of the hx diagram for humid air (see example).
Example:
See hx diagram for humid air page 13
Assumptions:
- Ambient condition: temperature 30°C, reI. air humidity 70%
- Lowest expected ambient temperature 18 °C, permissible relative air humidity =< 40%.
Determination of the permissible relative air humidity at which the air is to be dried at 30°C:
- Determine intersection of temperature 30°C and relative air humidity 70% (state of air
before drying)
- Determine intersection of temperature 18°C and relative air humidity 40% (nominal state of
air after drying)
- Read off the corresponding water vapour content for the nominal state of the air: 5g/kg air.
- Read off the intersection with the curve of the relative air humidity on the line for the water vapour
content vertically upwards at approx. 2 to 4°C above the initial temperature (30°C), selected
34°C: 15%.
Result of the example:
The air is to be dried for a lowest expected ambient temperature of 18°C to a relative air humidity
of 15%.
Connection of a sorption air dehumidifier to dry the air in the interior:
Pipe diameters vary according to the device used and are to be agreed with the manufacturer of
the sorption dehumidifier.
Drying is carried out in a closed circuit:
Process air
Hygrostat Equaliser pipe for leakage air
~~::;::::::------,+-- Line diameters vary according to the device
used.
TT Diameter of the leakage air equalisation
Leakage I VOITH I approx. 0.5 x diameter of process air lines .
.;, -~-------- ]q- Hygrostat

controlled air Humid air
dehumidifier
Regeneration air
\
Dehumidified air
2008-01-16 3625-006714en
airev-KHi Postfach 1555 . Tel. (07951) 32-0 . Fax 32-500
Page 12/13

Y'
/' '.'
L I'~
I'\.
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::::' .I '. }, '

, iN /1
,( ~,
0
M
.
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.{
.., ~',
,...
.. ' .. ! ,,'/
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1 -I Y ,1\. /.
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r\.:
0
r- 0 II\. .1
N
-..;, .'
0
"- I~~,
UI
hx-Diagramm feuchter L.uft

bei 1013 mbar
hx-hygrometric chart
out 1013 mbar
hx-diagramme hygrometrique
a 1013 mbar
10 40 ~O kPa
I--~_--.-"-..,.=.........,,...-,.~ -"1 -'---+-1--.--o.-~~--+i~--'-I_"------"""'j1'-,'____'''-.,..,_._-4-'---'~
o 5 10 15 20 25 <T.rT' Hg
Dampfdruck . vapour-pressure· pression de vapeur
2008-01-16 3625-006714en
airee-TRg Voith Turbo GmbH & Co. KG • 0-74555 Crailsheim Rev. 1
airev-KHi Postfach 1555· Tel. (07951) 32-0' Fax 32-500 Page 13/13
VOITH
Voith Turbo I Geared variable speed coupling I 5EC 56 Indonesia Pelabuhan I R 15 K 400 M
Table of contents
Appendix_B_
Operating fluids ISO VG 32 for hydrodynamic circuits with gearing
3625-006073
141
Operating Fluids ISO VG 32 for Types:
VOITM Voith Geared Variable Speed Couplings

and Torgue Converters with gear stage(s)
R, EAand EH
1. Field of AQQlication
This specification applies to:
geared variable speed couplings of type "R"
torque converters with gear stage(s) of types "EA" and "EH".
This list may not be applicable in individual cases involving special requirements. In such cases, the
appropriate specifications will be agreed when handling the order and/or stated in the instruction
manual.
2. Requirements to be fulfilled bv Ooeratina Fluids

Characteristic value Test procedure Test conditions Requirements Unit
Kinematic viscosity DIN 51562 40°C ISOVG 32 mm 2 /s (cSt)
ASTM D445
Viscosity index DIN ISO 2909 ~ 95
ASTM D2270
Density DIN 51757 15°C 850 - 900 kg/m 3
ASTM D1298 0.85 - 0.9 kg/L
Pour point DIN ISO 3016 similar or lower than -24 °C
ASTM D 97
Flash point DIN EN ISO 2592 higher than 175 °C
ASTM D92
Ignition temperature ***) DIN 51 794 higher than 250 °C
IEC 60079-4
Corrosive effect on copper DIN EN ISO 2160 3h at 100°C max. 2
ASTM D130
Protection against corrosion of DIN ISO 7120 Procedure A passed
steel ASTM D665
Demulsibility ISO 6614 Time in minutes at 54°C max. 30 minutes
ASTM D1401
Aging characteristic *) DIN 51587 1000 h bei 95°C increase of neutralization mg KOH/g
number max. 2
Aging stability (TOST) *) ASTM D943 95°C 1NZ = 2mq KOH/[ > 1000 h
Foaming behavior ISO 6247 Sequences I, II, III max. 15010, 7510, 15010 ml
ASTM D892
Neutralization number (new oil) DIN 51 558 please indicate mg KOH/g
ASTM D974
Air release property DIN ISO 9120 0.2% at 50°C max. 5 minutes
ASTM D3427
Mechanical test in the FZG gears- DIN 51354-2 or Test Al8,3/90 min. 10 **)
bracing-testing machine, failure DIN ISO 14635-1
load staqe
Compatibility with sealing material DIN ISO 1817 SRE-NBR 1 acc. to relative change in volume %
SRE-NBR 1 DIN 53 538-1, oto 12
DIN ISO 1817 in 7 days at 100°C change in hardness Shore A
connection wth o to - 7
DIN 53 505
*) alternative
**) < 10 only after individual approval
***) to be fulfilled for operation in hazardous agreas, Temperature Class T3 (max. surface temperature 200°C)
Viscosity on startup under the conditions prevailing on site with an oil supply provided by
- centrifugal pumps should not exceed 250 mm2/s,
- positive displacement pumps with sufficient input power (to be enquired) up to 1000 mm2/s.
Replacing:
3625-006073 dated 2007-03-08
I I
Date:2007-1 0-22/Shn 3625-006073 en
N Voith Turbo GmbH & Co. KG - 0-74555 Crailsheim
issued by: airee-TRg Revision 5
P.O. Box 1555 . Phone (07951) 32-0 . Fax 32-500
checked by: aire-HSi Page 1 /3
VOITN Voith Geared Variable Speed Couplings

and Torque Converters with gear stage(s}
R, EAand EH
3. Oil Selection by Operators and Mineral Oil Companies
Considering the requirements of section 2, the following types may be used:
- hydraulic oils HLP to DIN 51524 part 2,
- turbine oils to DIN 51515-1 and -2 with sufficient load-carrying capacity (FZG) for gear lubrication.
4. Selection of Oils
The following list contains hydraulic oils to DIN 51524 part 2, turbine oils to DIN 51515 as well as oils
that meet the requirements according to section 2 and oils that have proven well in practice under
normal operating conditions.
As the local conditions and the oil qualities vary, we cannot assume any liability for the oil itself
mentioned in this list. In case of negative operating result, warranty claims made in this connection will
not be accepted.
Supplier Designation Ignition temperature

higher than 250°C
ADDINOL Hydraulic Oil HLP 32 *) yes

Hydrod. Transmission Oil SGL 18 yes
Agip Blasia 32 yes
OSO 32 yes
AP OIL International Ltd. AP TORQUE OIL 32 no data
ARAL DEGOL BG 32 yes
Vitam GF 32 yes
AUTOL Hydraulic Oil HY-S 32 ISO yes
AVIA GEAR RSX 32-S yes
BHARAT HYDROL HLP-32 *) no data
BP Energol HL-XP 32 yes
Energol HLP-HM 32 yes
CALTEX Torque Fluid 32 no data
CASTROL HYSPIN AWS 32 no data
HYSPIN SP 32 no
CEPSA CEPSA EP 125 no data
CEPSA HIDRAULICO HM 32 no data
Chevron Hydraulic Oil AW 32 no data
Clarity Hydraulic AW ISO 32 no data
ConocoPhillips CONOCO Hydroclear AW Hydraulic Fluid 32 yes
ExxonMobil Mobilfluid 125 yes
Mobil NUTO H 32 yes
Mobil DTE 24 yes
FUCHS Europe Renofluid TF 1500 no data
Renolin ZAF 32 B no data
Renolin Eterna 32 *) no data
Gulf Oil Corp. Ltd. India Gulf Harmony AWT 32 *) no data
Hindustan Petroleum Corp. Ltd. ENKLO HLP 32 *) no data
Indian Oil Corporation Ltd. Servo Torque 10 no data
Servo System HLP 32 *) no data
KLOBER LUBRICATION Lamora HLP 32 *) yes
KNPC Kuwaitoil Hydraulic Oil ISO 32 no data
Kuwait Petroleum Intern. Lubricants Q8 Haydn 32 yes
Q8 Holst 32 yes
Q8 van Gogh EP 32 *) yes
MOGUL Koramo MOGUL HM 32 no data
MOGUL OT-HP3 no data
Date:2007-1 0-22/Shn 3625-006073 en

P.O. Box 1555 . Phone (07951) 32-0 . Fax 32-500
checked b : aire-HSi Pa e 2/3
VOITM Voith Geared Variable Speed Couplings

and Torque Converters with gear stage(s)
R, EAand EH
Supplier Designation Ignition temperature

higher than 250°C
OEST OEST HYDRAULIC OIL H-LP 32 no data

OMV OMV hyd HLP 32 yes
Petro-Canada HydrexAW 32 yes
Petro-Oil HYDROL HLP 32 no data
Petro bras LUBRAX INDUSTRIAL HR-32-EP no data
LUBRAX INDUSTRIAL EGF-32-PS *) no data
LUBRAX INDUSTRIAL TURBINA EP 32 *) no data
Petrol Ofisi Hydro Oil HD 32 no data
REPSOL TELEX E-32 yes
Shell Tellus 32 yes
Tellus S 32 yes
SK Corporation SK ZIC Supervis AW 32 *) no data
SRS Schmierstoff Vertrieb GmbH Wintershall WIOLAN HF 32 yes
Wintershall WIOLAN HX 32 yes
Statoil HydraWay HMA 32 yes
TEXACO Rando HD 32 yes
TEXTRANV32 no data
TOTAL Azalia ZS 32 yes
Valvoline Cummins Ltd. Valvoline HLP 32 *) no data
WISURA Kineta 32 V no data
*) Pour point higher than specified. Check viscosity on startup.
This list does not claim to be complete.
For an updated oil selection list, please contact Voith Turbo GmbH & Co. KG.
Date:2007-1 0-22/Shn 3625·006073 en

P.O. Box 1555· Phone (07951) 32-0' Fax 32-500
checked by: aire-HSi Page 3/3

BFP Hydrocoupling Manual by VOITH

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Voith Turbo VOITH

Geared variable speed coupling

KKS Cod~.'.(\,~ ,\~ 0"<: !\~ Vi\:t

Techn. Documentation No. 91800037910_BA1_en

If you have questions regarding the Geared variable

Voith Turbo GmbH & Co. KG

Service Center - Variable Speed Drives

Tel. +49 7951 321666

Fax +49 7951 32903

This Instruction Manual describes the technological

level of the Geared variable speed coupling at the

Subsequent changes in the design of the Geared va­

riable speed coupling are not incorporated in this In­

This Instruction Manual is protected by copyright

laws. It cannot be translated, duplicated (mechani­

cally or electronically) in whole or in part, or passed

on to third parties without the written approval of the

Date of issue: 2010-11-05

Techn. Documentation No. 91800037910_BA1_en

Overhaul Version Revision Date

0 1.00 First edition of disassembly / reassembly in­ 2010-11-05

Date Author Head of product group

2010-11-05 airpd / HSr airev / Graf

General information on the Instruction Manual

Operating personnel must

Maintenance personnel must

Service personnel must

Notes on using the Instruction Manual

Warnings regarding handling: Presentation of

Type of hazard ------,~

Consequences of the hazard -----,~

Summary of safety information and additional notes at the beginning of each

2. Signal word - Danger level

3. Type and source of the danger

5. Measures to take to reduce the hazard

Points to a location with important information regarding use and/or

List • identifies/marks individual items in a

List identifies/marks subitems in a list

Cross reference points to other chapters or segments

(DJ-+--­ 3.4 Lubrioation

t1'B che;ck ;,,':]I-.)e

Mi~ed -c~~.trc<i (vn the 0- ::;.,;::Ie';

:,0<}Ji~9 ',';.::.ter te~pe;.:rlure(;- under t:5-20 ~C

F~c",.. contrc-! 1,0'· th~ WoMer ~ide')

1.1 Machine data ......................................................................1

1.2 Operating data .....................................................................4

1.2.1 The Geared variable speed coupling ................................................... .4

1.2.2 Heat exchanger ....................................................................7

2 Safety information .. ............................................... ..8

2.1 Basic principles underlying the design of the equipment. ....................................8

2.2 Proper use of the equipment ..........................................................8

2.3 Improper use of the equipment ........................................................8

2.4 General safety information ............................................................9

2.4.1 Safety symbol .....................................................................9

2.4.2 Hazard classification ................................................................9

2.4.3 Maintaining and replacing safety symbols ...............................................10

2.4.4 Personal safety ...................................................................10

2.5 General safety information ...........................................................11

2.6 Organizational measures ............................................................12

2.7 Personnel selection and qualification, basic obligations ....................................13

2.8 Obligations of the operator ..........................................................13

2.8.1 Protection systems ................................................................14

2.8.2 Designating and instructing responsible individuals .......................................14

2.8.3 Obligations regarding information .....................................................14

Subsequent changes in the design of the Geared va

riable speed coupling are not incorporated in this In

laws. It cannot be translated, duplicated (mechani

0 1.00 First edition of disassembly / reassembly in 2010-11-05

(DJ-+-- 3.4 Lubrioation