058222016ID Fan Hydraulic Coupling-1210SVNL BESCL-BHILAI PDF

Customer:BESCL - BHILAI
Version Nos.088 S 000 110 to 113
CHAPTER
Instruction manual 1
Disassembly / Reassembly Manual 2
Drawings, Schematic Drawings, Diagrams 3
Parts List 4
Attaching Parts 5
VOITH TURBO
POWERTRANSMISSION
VARIABLE SPEED TURBO COUPLING
Type: 1210 SVNL 21-22.5

Code : BESCL, BHILAI (BHEL-RANIPET)
Version Nos. 088 S 000 110 to 113
Serial Nos. 113-00110 to 113
Instruction Manual
VOITH TURBO
POWERTRANSMISSION
Should you have any question with regard to the VARIABLE SPEED TURBO COU-
PLING, please contact the Service department (SMs) of the product group variable
speed drives of Voith Turbo Pvt. Ltd., Hyderabad stating the serial number.
Voith Turbo Pvt. Ltd.

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

Fax : +91 40 27171141
E-mail : vtip.service@voith.com
Service department of the product group variable speed drives

SMs
Telephone : dial the above nos.
E-mail : Prasad,Chelluboina (Chelluboina.Prasad@Voith.Com)
This instruction manual describes the technical state of VARIABLE SPEED TURBO
COUPLING on delivery.
Any later modifications on the VARIABLE SPEED TURBO COUPLING are not con-
sidered in this instruction manual.
2007
This instruction manual is protected by copyright. It is neither allowed to translate or

copy it (by mechanical or electronic or any other process) as a whole or in parts,
nor to submit it to third parties, without the publisher’s written approval.
Date of issue : 04/2007

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

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

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

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

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

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

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

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

Type 1210 SVNL 21-22.5
Code : BESCL, BHILAI - BHEL, RANIPET
Version Nos -088 S 000 110 to 113
Serial Nos. 113 - 00110 to 113
1.1 Machine Data
VARIABLE SPEED
TURBO COUPLING
Rotation seen in direction of the power flow CCW
Scoop tube stroke 320 mm
Power requirements of driven machine Pa 1672KW
Motor speed ne 740 rpm
Min.slip (Approx.) s 3.6%
Max.output speed na, max 715 rpm
Regulating range 5:1 downward
Oil tank filling capacity 780 L

APPROX.
Required oil viscosity ISO VG32
Weight (without oil ) [approx.] 3700 kg
Noise emission :1
• Measuring surface sound pressure level Lpa 85 dB
1 Measurement to DIN 45 635 Part 1 and 23

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

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

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

feed back transmitter
Model 0816 Make: Keltron
Connecting couplings
Input end Unique Transmissions Ltd.

Model : 80CC-600Q - 10 mm gap.
Output end Unique Transmissions Ltd.

Model : 80LQ-600 - 220 mm gap
Heat exchanger
Type of cooler & Make Duplex - United Heat Exchangers.
Instruments
See part 5 “Attaching parts” in this documentation
) Regarding a detailed documentation of the above mentioned components,

please refer to part 5 “Attaching parts” of this documentation.
2
1 Technical Data 1.2 Operating data
1.2 Operating data
1.2.1 VARIABLE SPEED TURBO COUPLING
Temperatures( )1
Working oil temperature down- Operating range < 95°C

stream of scoop tube (18) Alarm at > 100°C

stream of scoop tube (18.1) Shut down at > 110°C
Oil temperature upstream of oil Operating range < 90°C

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

Heat exchanger (15)
stream of cooler (33) Alarm at > 80°C

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

transmitter (16)

Switch ( 17 ) Alarm < 0.8 bar

Switch ( 17.1 ) Shut down < 0.6 bar
Differential pressure indicator Operating range ~ 0.3 bar

cum switch across the double Alarm > 0.6 bar
oil filter(41) (Manual change-
over of double fil-
ter)
Oil pressure at test connection Operating range as per above val-

(55.1 & 55.2) ues at measur-
ing points 16; 17
1 The item numbers shown in brackets indicate the measuring points according to ) the function and
measuring point diagram in part 3 “Schematic drawings”.
3
1 Technical Data 1.2 Operating data
Oil flow rates
Working oil flow rate ~ 440 l/min
Lube oil flow rate to the VARIABLE ~ 10 l/min

SPEED TURBO COUPLING at 0.3bar
Actuator
Actuating speed 60Sec / 90°
1.2.2 Heat Exchanger ( 8400 40 380)
Heat Exchanger Working oil Shell chamber Tube chamber

(Oil-ISO VG32) (Water)
Flow rate, m3/hr 27 32
Working temperature Inlet/Outlet, °C 86.72 /63 38/46
Design temperature, °C 120 70
Design pressure, kg/cm2g 10 10
Hydrostatic test pressure, kg/cm2g 15 15
No. of passes 1 2
4
2 Safety Information
2.1 Meaning of symbols and notes
Danger!
This symbol signals an imminent danger to the life and health of people.
If this note is not observed, injury to health and even most serious injuries
may be the consequence.
Warning!
This symbol signals a harmful situation.

If this note is not observed, the product may be damaged.
Note!
i This symbol refers to proper handling of the product. It does not refer to or indicate
a dangerous situation.
#
Attention!
This symbol refers to components incorporated in the product, which may be

destroyed by static electricity.
2.2 Use in accordance with the regulations
• The VARIABLE SPEED TURBO COUPLING is provided to transmit power wearfree

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

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

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

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

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

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

nance and repair of VARIABLE SPEED TURBO COUPLING,
• Non-observance of the information with regard to the safety at work and of the
product contained in the instruction manual,
• Filling the VARIABLE SPEED TURBO COUPLING with contaminated oil, with
different oil types or with an oil type not included in the list authorized by Voith or
not approved by Voith.
Note!
i It is only allowed to do repair work on the VARIABLE SPEED TURBO COUPLING

during the warranty period, after Voith Turbo Pvt. Ltd., Hyderabad gave their
approval.
8
3 Design and Operation
3.1 Design
Illustration 1 Design of VARIABLE SPEED TURBO COUPLING
1 Housing With Oil Tank 6 Shell 12 Filling pump

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

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

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

The working oil temperature depends on the power losses (slip) and the working oil
flow rate and is monitored by temperature measuring instruments.
Fusible plugs
If the oil temperature rises to 160º C (320º F) due to a failure, the solder of fusible
plugs in the coupling melts and oil is thrown into the housing of VARIABLE SPEED
TURBO COUPLING. The coupling drains the oil, thus reducing torque transmis-
sion.
11
3 Design and Operation 3.3 Speed control
3.3 Speed control

Illustration 2
Speed control by means
of Scoop tube
1.Actuator
2.Scoop tube rods
3.Scoop tube
4.Oil ring
5.Sc.tube position-0%
6.Sc. tube position-100%
The speed of driven machine may be controlled steplessly. For this purpose, the
coupling oil filling is changed during operation by means of the movable scoop
tube:
• Scoop tube inserted as far as possible in the scoop chamber of coupling (0%
position): minimum oil ring, minimum output speed.
• Scoop tube moved as far as possible out of the scoop chamber of coupling
(100% position): maximum oil ring, maximum output speed.
12
3 Design and Operation 3.4 Lubrication
3.4 Lubrication
3.4.1 Self-lubrication
Bearings and gears of VARIABLE SPEED TURBO COUPLING need to be lubri-
cated prior to and during operation.
Lube oil circuit

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

and align roughly.
3. Grout the foundation bolts and foundation rails or plates with concrete and let it
harden.
Illustration 5
Grouting the concrete
foundation
1 Shim (10mm)
2 Adjusting screw
3 Filling compound
4 Shim
5 Tamped concrete
6 Foundation rail (or)
Foundation plate
7 Concrete compound
4. Adjust the coupling height using the supplied adjusting screws.
) Regarding measurements: please see section5.5 "Machine alignment"
i
Note!
All machines involved (driving machine, VARIABLE SPEED TURBO COUPLING,
driven machine) should be installed prior to alignment.
5.4.2 Setting down on a steel foundation
Setting down
1. Set the variable speed turbo coupling down on the steel foundation using the
suitable lifting appliance. Observe the axial clearance of connecting couplings in
this case.
2. Adjust the coupling height using the supplied adjusting screws.
3. Shim the coupling using the supplied and greased shims. Adjust the lateral posi
tion of coupling by shifting the coupling on the shims using the adjusting screws.
26
5 Assembly 5.5 Machine alignment
) Regarding measurements: please see section5.5 "Machine alignment"

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

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

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

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

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

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

displacements
Radial displacements
horizontal ∆ H
Axial displacement ∆ L1
Axial displacement ∆L2
This means that the shafts, connected with connecting couplings,
Radial displacement horizontal ∆H 0.66 mm
Axial displacement1
• Input end ∆ L1 0.82 mm
• Output end ∆L2 0.76 mm
1 Assumed housing temperature on installation 20º C (68º F), during operation 80º C (176 º F)
Values correspond to the maximum possible shaft misalignment including bearing clearance.
shall not be in alignment during standstill, but must be provided with a radial/angu-
lar/axial offset. This offset compensates the misalignment to be expected at start-
up and during operation.
28
Alignment tolerance at When turning the shafts jointly by 360º:

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

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

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

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

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

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

3. Radial runout check of the already aligned machine(1): Turn shaft (1) by 360º.
Value to be aimed at: dial gauge deflection ≤ 0.02 mm; permissible value:
) Instruction manual of driven machine.
Precision alignment
Vertical plane
4. Reset dial gauge to the initial value.
5. Turn shaft (2) by 180º.
6. Enter the dial gauge deflection in the coordinate system of the installation
check form.
Illustration 9
Example for radial
measurement A and
angular measurements B
and C in vertical plane
Evaluation :
Radial measurement A :
Radial offset vertical = 5.00-4.66 = 0.17 mm
2
Angular measurements B+C :
Angular displacement vertical = 6.55-5.45 = 0.55 mm
2
30
Applicable to the angular measurements is : half the difference of the two angular
measurements is the dimension of angular displacement
7. Correct vertical radial offset and vertical angular displacement by means of the
adjusting screws.
Precision alignment
Horizontal plane
8. Move the alignment device (3) in horizontal position (turn by 90º against the
original position).
9. Repeat the measurement.
Illustration 10
Example for radial
measurement and
angular measurements
in horizontal plane
Evaluation :
Radial measurement A :
Radial offset vertical = 5.28-5.00 = 0.14 mm
2
Angular measurements B+C :
Angular displacement vertical = 4.65-4.55 = 0.05 mm
2
10 Move the VARIABLE SPEED TURBO COUPLING in horizontal direction using

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

between driving machine and VARIABLE SPEED TURBO COUPLING, i.e., there is
no space between the shaft ends.
Rough alignment
Prior to precision alignment it is advisable to first align the machines roughly using
a thickness gauge and a ruler.
31
5.6 Machine fixing
Illustration 13
Foundation fixing
1 VARIABLE SPEED
TURBO COUPLING
2 Foundation screws
3 Adjusting screws
4 Shims
5 Foundation
1. Put shims (4) under the coupling housing for all foundation screws. Please
observe that all shims bear the load uniformity.
2. Turn the adjusting screws (3) back.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

and 100% position at desired speed.
Rundown
Operating conditions Action Result

Scoop tube at 0% position Coupling drains. Driven
machine runs at minimum
speed.
Lube oil pressure < 0.6 bar Driving machine OFF Driving and driven
machine run down to
stop.
Bearings are no longer

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

stream of scoop tube Alarm at > 100º C
(measuring point 18 )
Working oil temperature Operating range < 100°C

downstream of scoop tube Shut down at > 110°C
(18.1)
Oil temperature Upstream Operating range < 90º C

of oil cooler (measuring
point 23.1)
Oil temperature Down- Operating range < 70º C

stream of oil cooler(meas-
uring points 15)

downstream of cooler (33) Alarm at > 80°C

downstream of cooler Shutdown at > 90°C
(33.1)
) Regarding position of measuring points please see "Oil Circuit and Measuring
Point Scheme" in part 3, "Drawings" of this documentation.
Fusible plugs
The fusible plugs respond at a working oil temperature of 160º C (320º F) in the
working chamber thus preventing an overheating of coupling.
Reasons for a temporary thermal rise of working oil temperature might be:
• Cooler does not function properly

• Overload of coupling
49
Consequences of melted fusible plugs:
- the control behavior of the coupling changes slightly

- max. output power is almost reached
- the oil temperature in the oil tank rises slightly
Pressures
Working oil / lube oil
Lube oil pressure at pressure Operating range 0.3 bar

transmitter (measuring point 16)

transmitter (measuring point 17) Alarm at < 0.8 bar

Switch ( 17.1 ) Shut down < 0.6 bar
Lube oil pressure at the differ- Operating range < 0.3 bar
ential Pressure Indicator cum Alarm at > 0.6 bar (Manual changeover
switch accross double filter(41) of double filter)
Oil pressure at the test connec- Operating range as per above

tion (measuring point mentioned values at
55.1&55.2) measuring points 16; 17
) Regarding position of measuring points please see "Oil Circuit and Measuring
point Scheme" in part 3 "Drawings" of this documentation.
Oil Level
Oil level check

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

0% scoop tube position
h2 = Fill level range at

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

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

COUPLING and assembly of the oil piping, dirt may enter the VARIABLE SPEED
TURBO COUPLING.
Therefore, check the condition of the double oil filter during commissioning and
clean (even several times), if necessary.
51
Flood the clean

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

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

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

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

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

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

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

or reverse rotation:
• inspect the bearings and fusible plugs

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

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

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

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

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

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

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

element
7. Clean the clogged outside for filter element (5) using gasoline for cleaning pur
poses, "Eskabon" or diesel oil"; for this purpose wash the filter outside from the
top to the bottom using a brush. Do not submerge the filter element in the clean
ing agent.
Reistalling the filter 8. Blow the filter element from the inside to the outside using compressed air.
element
9. In the event that the filter element is heavily clogged, repeat the cleaning proce-
dure, if necessary.
10. Check filter element and O-rings for any damage
11. Slide the cleaned O-rings (6+7) on the filter element
12. Insert the cleaned filter element (5) into the housing hollow shaft
13. Screw the cleaned filtering jug (2) together with the O-rings (6+7) into the hous-
ing.
14. Close the vent screws (3)
15. Fill the filtering jug (2) with oil (section "Flood the clean filtering jug" on page
52).
58
8 Maintenance and repair 8.3 Inspection of hose lines
8.3 Inspection of hose lines
Storage
• Storage period: max. four years from the date of manufacture
• Ambient conditions: dry rooms without direct solar radiation
Use
• Period of use: max. six years, depending on the application and surroundings
i Note!
The date of manufacture is printed on the hose lines. Example: 4 Q 95 (year of

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

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

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

and pressures
Connecting cou- Manufacturer's instructions

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

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

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

Check the pipe work for leaks (take measures
to prevent damage to the environment, if nec-
Lube oil flow too low essary)
to give release for
start • Double oil filter clogged • Changeover double oil filter and clean the fil-
tering jug.
Check the differential pressure monitoring.
Differential pressure • Double oil filter clogged • Changeover double oil filter and clean the fil-
at double oil filter too tering jug.
high
• Double oil filter clogged • Changeover double oil filter and clean the fil-
Lube oil pressure too tering jug.
low during normal
operation
• Oil temperature in the oil tank < 45 • Warm up the oil tank to > 45°C (113 °F)
Filling pump pressure °C (113 °F), thus air release prop-
too low erty too low
• Oil level too low • Check oil level and top up to a value between
minimum and maximum mark. Check fusible
plugs.
• Oil foaming (oil temp. too low; oil Check the oil for impurities. Centrifuge or sepa-
contains water; poor air release rate the oil. Change the oil, if necessary.
property; wrong oil quality)
64
9 Trouble shooting 9.4 Temperatures
9.4 Temperatures
• Cooling water flow rate too low • Increase the cooling water flow rate
• Cooling water too warm • Check and clean the cooling system
• Cooler is contaminated
VARIABLE SPEED
TURBO COUPLING • Operation of VARIABLE SPEED • Operate the VARIBLE SPEED TURBO
becomes too hot dur- TURBO COUPLING outside the per- COUPLING within the characteristic curve
ing operation mitted characteristic curve
• Fusible plugs responded • Find and eliminate the cause. Insert new
fusible plugs
• Bearing damage • Check quiet running

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

• Insufficient shimming between • Check alignment and shimming and correct,
Uneven running vibra- machine and foundation (foundation if necessary
tion and noise rail); the support is not uniform;
machine is distorted
• Foundation bolts are loose, the foun • Check the foundation and retighten the foun-
dation is defective, foundation frame/ dation bolts, if necessary.
rail is not grouted
• Wear or insufficient lubrication of con- • Check the connecting couplings, the lube oil
necting coupling; sleeve for curved supply and injection nozzle.
tooth couplings cannot be displaced
axially
(gearing shows running marks)
• Unbalance of rotating parts • Measure the vibration and make a frequency

• Bearing damage analysis of the whole system. Record meas-
uring values and operating data.
• Check and replace bearings, if necessary.
66
9 Trouble shooting 9.6 Cross references
9.6 Cross references
Subject Relevant documentation
Oil cooler Oil cooler manual in part 5 “Attaching parts” of this documentation
Alignment section 5.5 “Machine alignment” on page 27
Operating data (pressures, section 1.2 “Operating data” on page 3

temperatures, oil flow rates) section 7.3.1 “Machine monitoring” on page 49
Foundations section 5.6 “Machine fixing” on page 33
Oil section 8.4 “checking the oil for water content and impurities” on page 59
Oil level section 6.2 “Operating oil fill” on page 42
section 7.3.1 “Machine monitoring” on page 49
Fusible plugs section 8.5 " Replacement of fusible plugs" on page 60
Lube oil filter section 8.2 " Cleaning the double oil filter" on page 57
Connecting couplings Manual for connecting couplings in part 5 "Attaching parts" of this documentation
67
VOITH TURBO
POWERTRANSMISSION
Type: 1210 SVNL 21-22.5

Version Nos.088 S 000 110 to 113
Serial Nos. 113-00110 to 113
Disassembly / Reassembly Manual

VOITH TURBO
POWERTRANSMISSION

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

Fax : +91 40 27171141

SMs
2007


Version : 0.00
Printed in India
VOITH TURBO
POWERTRANSMISSION
Contents of
Disassembly / Reassembly
10 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10.1 Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10.2 Tools and auxiliary means . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.3 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.4 General view of assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
11 Survey of general overhaul. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

11.1 General overhaul of the machine . . . . . . . . . . . . . . . . . . . . . . . . 71
11.1.1 How to disassemble the machine . . . . . . . . . . . . . . . . . . . 71
11.1.2 Machine assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11.2 Recommissioning of the machine. . . . . . . . . . . . . . . . . . . . .. 73
12 Removal and installationof assemblies. . . . . . . . . . . . . . . . . . . 74

12.1 Scoop tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
12.1.2 Checks, measurements and maintenance. . . . . . . . . . . . . 76
12.1.3 Installation of scoop tube. . . . . . . . . . . . . . . . . . . . . . . . . . 76
12.2 Adjusting scoop tube stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
12.3 Adjustment of optimal scoop tube position. . . . . . . . . . . . . . . . . 81
12.4 Replacement of fusible plugs removal of filling pipe. . . . . . . . . . 83
12.5 Filling pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
12.5.1 Removal of filling pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
12.5.3 Re-installation of filling pump. . . . . . . . . . . . . . . . . . . . . . . 85
12.6 Coupling runner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
12.6.1 Removal of coupling runner. . . . . . . . . . . . . . . . . . . . . . . . 87
12.6.3 Installation of coupling runner . . . . . . . . . . . . . . . . . . . . . . 88
13 How to disassemble and reassemble assemblies . . . . . . . . . . 90
13.1 Coupling runner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
13.1.1 How to disassemble the coupling runner. . . . . . . . . . . . . . 91
13.1.2 Checks, measurements and maintenance1. . . . . . . . . . . . 93
13.1.3 Assembly of coupling runner . . . . . . . . . . . . . . . . . . . . . . . 93
13 How to disassemble and reassemble assemblies . . . . . . . . . . 90
13.1 Coupling runner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
13.1.1 How to disassemble the coupling runner. . . . . . . . . . . . . . 91
13.1.2 Checks, measurements and maintenance1. . . . . . . . . . . . 93
13.1.3 Assembly of coupling runner . . . . . . . . . . . . . . . . . . . . . . . 93
10 Introduction
observed in addition to the different individual information.
Warning!
Hang the VARIABLE SPEED TURBO COUPLING only on the marked suspen-
sion points (label)!.
The suspension points located on the VARIABLE SPEED TURBO COUPLING

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

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

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

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

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

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

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

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

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

see part 5 "Attaching Parts" of this instruction manual).
3. Re-assemble all disconnected lines and pipes.
i Note!
Filter the operating oil during filling (grade of filtration 30 µm or finer).
4. Fill in the operating oil.
5. Re-connect all electric lines.
6. Check the function of filling pump, scoop tube actuator and indicator.
7. Check the oil cooler for leaks and vent the oil cooler
i Note!
Observe the job instruction in chapter 6 "Commissioning " of the instruction manual
for test run preparation and performance.
8. Perform a test run with the VARIABLE SPEED TURBO COUPLING (Please see
section 6.3.2. "Test run performance" on page 44 in the instruction manual).
Check function, observe quiet running, temperatures and oil pressures. Check
the oil level after some time.
73
12 Removal and installation of assemblies
i Note!
Screw tightening torques are not mentioned in the text, but exclusively in the
attached sectional drawings.
12.1 Scoop tube
) The following attached sectional drawing(s) are the basis for this section
- 740 090 131 Assembly - horizontal section.
Designation Item No.
Scoop tube housing 201/010
Bellows 201/060
Cover 201/030
Hex.bolt 201/050
Shaft sealing ring 201/160
Sleeve 501/020
Roll pin 501/030
74
12 Removal and installation of assemblies 12.1 Scoop tube
Warning!
ment.
Make sure to collect any oil leaking out of the control oil lines in an appropri-
ate container.
Steps to be taken
1. Separate Connecting rods from scoop tube. Loosen the actuator and turn it side-
ways. Remove bellows.
2. Dismantle cover to replace the shaft sealing ring. Carefully withdraw the
scoop tube.
i Note!
Do not bend the scoop tube on removal.
3. Carefully remove the connecting rod together with sleeve and scoop tube from
the scoop tube housing and set down on a clean, soft base.
4. Check the shaft-sealing ring.
i
Note!
Replace the shaft-sealing ring when oil is in the bellows or when the shaft-sealing
ring shows any damage. Observe the job instruction in the following section "
Removal of shaft sealing ring" in case the shaft-sealing ring needs to be replaced.
75
Removal of shaft sealing ring
Steps to be taken
1. Remove the socket head screws.
2. Remove the cover from the scoop tube housing.
3. Remove the shaft-sealing ring from the cover or the scoop tube housing.
4. Apply sealing compound to the outer surface of the new shaft-sealing ring and
press it into the cover up to the stop in the correct position.
5. Apply sealing compound to the cover and mount it on the scoop tube housing so
that the vent holes for the bellows point downward.
12.1.2 Checks, measurements and maintenance
• Visually check the scoop tube and the scoop tube mouth for wear.
• Check whether the scoop tube can move easily in the scoop tube housing.
• Clean all components.
12.1.3 Installation of scoop tube
Re-installation of the existing scoop tube
Steps to be taken 1. Slide the bellows in the correct position on the scoop tube.
i Note!
Insert the scoop tube into the scoop tube housing so that the word "OBEN"
stamped in the sleeve is on top.
2. Wet the scoop tube with oil and insert it carefully into the scoop tube housing
together with the sleeve and the adjusting rod.
3. Mount the lever on the scoop tube actuator using the adjusting rod
76
4. Connect the bellows with the scoop tube housing and the sleeve.
5. Check smooth running of the scoop tube over the whole regulation range by
slowly turning the VARIABLE SPEED TURBO COUPLING.
6. Check the scoop tube stroke (please see section 12.2 "Adjusting the scoop tube
stroke" on page 80).
Installation of new scoop tube
Steps to be taken
1. Remove the roll pin at the connection from the shaft joint to the sleeve.
Warning!
Scoop tubes depend on the direction of rotation (seen from the driving
motor) of the VARIABLE SPEED TURBO COUPLING.
Make sure to use the scoop tube for the correct direction of rotation ("clock-
wise or "Counter clockwise").
2. Check whether the scoop tube is suitable for the direction of rotation of VARI-
ABLE SPEED TURBO COUPLING. The scoop tube is marked as follows at the
shaft end:
Direction of rotation Mark

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

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

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

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

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

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

H (mm)
1210 SVNL 21-22.5 Counter Clockwise 320
4. Align the stop for stroke limitation (maximum output power) with the scoop tube
actuator and tighten.
80
12 Removal and installation of assemblies 12.3 Adjustment of optimal scooptube position
12.3 Adjustment of optimal scoop tube position
i Note!
The optimal scoop tube position needs to be adjusted only if the scoop tube was
replaced.
Warning!
The following jobs are performed with the VARIABLE SPEED TURBO COU-
PLING running. During operation, there are flow forces acting on the scoop
tube having a twisting, pulling or pushing effect.
Improper handling may damage the VARIABLE SPEED TURBO COUPLING.
Steps to be taken
1. Start the unit.
2. Operate the scoop tube over the whole positioning range (scoop tube positions
0% to 100%) by means of the scoop tube actuator.
Adjusting the
scoop tube Adjust the scoop tube in case of axial scoop tube vibration or high sound pressure
level:
Illustration 6
Adjusting the scooptube
1 Sleeve
2 Fixing bolt
3 Scooptube
4 Torsion rod
5 Scoop tube for “CW”
rotation
6 Scoop tube for “CCW”
rotation
7 word “OBEN”
3. Move the scoop to the position with maximum vibration.
4. Insert the torsion rod into the bore hole.
Warning!
Do not turn the scoop tube more than 40º in one direction!
81
12 Removal and installation of assemblies 12.3 Adjustment of optimal scooptube position
5. Unscrew the fixing bolt and turn the scoop tube to the most favorable
position by means of the torsion rod.
6. Repeat the steps 3 to 5 at other scoop tube positions until there is minimum vibra
tion over the whole scoop tube positioning range.
7. Stop the unit.
8. Remove the scoop tube, bellows and scoop tube actuator.
9. Bore the removed scoop tube together with the sleeve and pin with the roll pin.
10 Stamp in the direction of rotation of VARIABLE SPEED TURBO COUPLING on

the sleeve (please see illustration 6 "Adjusting the scoop tube" on page 81).
11 Re-install the scoop tube, bellows and scoop tube actuator.
12 Check free movement of scoop tube over the whole positioning range by slowly
turning the VARIABLE SPEED TURBO COUPLING.
13 Check the scoop tube stroke according to section 12.2 " Adjusting the scoop
tube stroke" on page 80.
82
12 Removal and installation of assemblies 12.4 Replacement of fusible plugs, removal of filling pipe
12.4 Replacement of fusible plugs, removal of filling pipe
Sectional drawings
)The following attached sectional drawings are the basis for this section.
- 740 090 131 Rotating parts
- 740 090 130 Vertical section
Item numbers
Designation Item Number
Inspection cover 301/ 070
Hex. screw 301/ 090

Fusible plugs 101/070/030
Primary wheel 101/070
Steps to be taken
1. Unscrew the inspection cover from the VARIABLE SPEED TURBO COUPLING
HOUSING.
2. Replace the fusible plugs in the primary wheel. In case that fusible plugs resp-
onded due to overheating of the VARIABLE SPEED TURBO COUPLING, elim-
nate the cause for the excessive temperature before inserting new fusible plugs.
4. Seal, mount and tighten the inspection cover.
83
12 Removal and installation of assemblies 12.5 Filling pump
12.5 Filling pump
Sectional drawings
- 740 090 131 Horizontal section
Item numbers

Soc.Hd. screws 701/090
Soc.Hd. Screw 701/100
Pump cover 701/050
Bearings 701/040
Drive pinion 701/020

Driven pinion 701/030
12.5.1 Removal of filling pump
The filling pump is located on the input side of the variable speed turbo coupling
below the primary shaft and can be dismantled after unscrewing the holding down
bolts.
Remove the pump cover and the assembly cover on the left of the input shaft. For
unscrewing the screw(701/090), the input shaft must be held. Turn out the screw by
10mm then loosen the gear from the centering by careful meats on the screw head.
Now, hold the gear by hand, disassemble it from the shaft and remove it via the
assembly hole.
In case of damages on the filling pump drive tooth, replace the two gear wheels.
For this, remove the complete coupling rotating parts from the housing.
i Note!
If the spur gear of the filling pump is larger than the pump housing diameter in the
coupling housing, it is necessary to remove the housing cover for removal of filling
pump.
i Note!
Ensure that the roll pins do not fall into the oil tank when removing the spur gear.
84
12 Removal and installation of assemblies 12.5 Filling pump
Removal of bearings 6. Press out the bearings, the two pinions and the possibly existing spacer rings.
and pinions
• Visually check all parts removed for damages
• Check contact pattern of drive pinion
• Clean all components
12.5.3 Re-installation of filling pump
i Note!
Prior to installation, wet all filling pump parts with operating oil.
Steps to be taken 1. Install the plain bearings so that the oil compensation groove points in direction
of the pinion gearing.
2. Install the drive pinion in the correct position (see the following table):
Direction of rotation of input Position of driven pinion

shaft and spur gear
Counter clockwise Left-hand side

Clockwise right-hand side
Illustration 8
Installation of drive
pinion on “clockwise”
or “counterclockwise
rotation”
85
12 Removal and installation of assemblies 12.6 Coupling runner
i Note!
On installation observe that the gears match.
3. Install the spur gear.
4. Measure the backlash. Permissible backlash range :0.2 mm … 0.3 mm
12.6 Coupling runner
Sectional drawings
Item numbers
Primary shaft 101/100
Secondary shaft 101/220
Labyrinth cover 201/145
O-ring 201/130
Hex. screw 201/150
Slotted round nut 101/190
Lock washer 101/200
Angular cont ball bearing 101/180
Scoop tube-housing 201/010
Coupling housing 301/010
Key 101/360
Angular cont ball bearing 101/230
Cyl. Roller bearing 101/050
Hex. screws 201/020
86
12.6.1 Removal of coupling runner
Prerequisites Prior to removing the coupling runner:
Warning!
ment.
Make sure to collect the operating oil in an appropriate container.
• Drain the operating oil.

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

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

• Remove the labyrinth drainpipes.
Steps to be taken
1. Suspend the VARIABLE SPEED TURBO COUPLING on the lifting appliance
and lift it off the foundation.
2. Put the VARIABLE SPEED TURBO COUPLING on an appropriate base so that
it can be titled to the input side.
3. Remove connecting coupling hubs and keys from the primary and secondary
shaft.
4. Disassemble the labyrinth cover on the primary side and the slotted round nut.
5. Remove the filling pump drive. Proceed as mentioned in section 12.5.1
"Removal of filing pump" on page 84.
6. Tilt the VARIABLE SPEED TURBO COUPLING carefully to the input side.
i Note!
Support the VARIABLE SPEED TURBO COUPLING housing, e.g. by means of
wood beams.
7. Loosen the hex. screws and press the scoop tube housing off the coupling
housing.
8. Screw the swivel into the secondary shaft centering thread.
87
Illustration 9
Coupling runner
suspended on lifting
appliance
1 Lifting appliance
2 Swivel
3 Secondary shaft
5 Coupling housing
9. Suspend the VARIABLE SPEED TURBO COUPLING at the swivel on an appro-

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

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

Shell 101/010
Shell cover 101/015
Hex. bolt 101/017
Spring washer 101/018
Bearing ring 101/020
Hex. Screw 101/030
Cyl.Roller bearing 101/050
Circlip 101/060
Fusible plug 101/070/030
Flat Sealing ring 101/070/040
Hex. Bolt 101/110
Primary shaft 101/100

Hex. Bolt 101/160
Ball bearing retaining ring 101/130
90
13 How to Disassemble & reassemble Assemblies 13.1 Coupling runner
Oil thrower 101/250

Hex. screw 101/150
Lube ring 101/240
Cyl.Roller bearing 101/180
Slotted round nut 101/190
Lock Washer 101/200
Fitted key 101/360
Secondary shaft 101/220
Secondary wheel 101/260
Ang.contact ball bearing 101/230
Isolating disc 101/500
13.1.1 How to Disassemble the coupling runner
Prerequisites
• Prior to disassembling the coupling runner, remove it from the VARIABLE SPEED
TURBO COUPLING, Regarding steps to be taken and information required for
removal, please refer to section 12.6.1 "removal of coupling runner" on page 87.
• Set the coupling runner down with secondary shaft on top and secure it against
displacement or tilting.
Illustration 11
Coupling runner set

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

carefully into the shell with the bolted on bearing ring and mounted bearing inner
race.
Warning!
Tilt the coupling runner by means of appropriate lifting appliances only and
secure it against displacement or tilting!
9. Bolt the primary wheel with the shell observing the tightening torque.
10. Tilt the coupling runner so that the free secondary shaft end is on top.
11. Press the bearing outer part into the scoop tube housing and secure it.
12. Slide the scoop tube housing on the secondary shaft.
13. Mount the circlip.
i Note!
Please observe the correct installation position of the bearings according to draw-
ing 740 090 126 (Assembly - Horizontal section) & 740 090 125 (vertical section).
14. Mount the bearings between scoop tube housing and secondary shaft.
15. Mount the bearings using the device according to illustration 14 "(special tool)
until they abut the shaft collar.
94
Illustration 14
Mounting device for

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

17. Install the labyrinth cover with the 0-ring on the secondary side.
18. Tighten the hex. screws with the seal rings cross wise using the specified tight-
ening torque.
19. Install the coupling runner (please see section 12.6.3" Installation of coupling
runner on page 88)
95
VOITH TURBO
POWERTRANSMISSION
Type: 1210 SVNL 21-22.5

Version Nos.088 S 00110 to 113
Serial Nos. 113-00110 to 113
Drawings / Schematic Diagrams / Drawings

VOITH TURBO
POWERTRANSMISSION

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

Fax : +91 40 27171141

SMs
2007


Version : 0.00
Printed in India
Horizontal section ...................................................... ........... 740 090 131
Vertical Section........................................................... ........... 740 090 130
Assembly plan for turbo coupling .............................. ........... 740 100 619
Arrangement Drawing.............................................................740 100 620
Function and measuring point diagram ..................... ........... 740 100 524
Terminal Plan.................................................. ........... ............ 740 100 335
Logic Diagram.........................................................................740 100 336
Connecting coupling (Input) ...................................................306840040390
Connecting coupling (output)..................................................306840040400
Oil Cooler................................................................................3068400403800
VOITH Specification sheets
Preservation of VOITH TURBO COUPLING ............. ........... 740 080 245
Operating fluids ......................................................... ........... 740 080 246
Criteria for oil change ................................................ ........... 740 080 247
Water content of oil.................................................... ........... 740 080 248
Recommended Types of oil for use.........................................740 080 077

Preservation & Packing Specifications of
VOITH TURBO Coupling type "R,S,TP,T, Brake VHBT" -1-
TORQUE CONVERTER "E"
This data applies to the protection of internal and external surfaces (as far as the surfaces have no
corrosion-resistant surfaces or are not made of silumin) as well as to packing of goods to be consigned
Transport method / Packing External Preservation

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

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

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

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

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

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

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

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

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

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

Air release property: 5 min. at 500 C DIN 51381
Aging stability
No corrosion, sediments or precipitation, even on entry of water
Starting viscosity under the conditions applying at the location of use is not above 250 mm2/s (cSt), for
gear pumps with adequate input power (refer to works) upto 400 m2/s.
3. Requirements for special cases:
Viscosity restrictions or differing viscosity range at extreme operating temperatures (to be particularly
specified)
4. Selection of types available from suppliers and oil companies:
Under consideration of the requirements (section 2 and sheet No:740080077), the following types may be
used.
Hydraulic oils H-L 32 to DIN 51523 Part I
It must be monitored that there is sufficient air release property (behaviour of the pump pressures and
control stability).
Any unsatisfactory operating results lead to the omission of any associated claims under warranty.
5. Recommended types of special oils for hydrodynamic power transmission:

(See data sheet NO.740080077)

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

If NZ rises by ≥ 2.0 mg KOH/g oil above the value when new, the oil has to be changed.
2. Water content (DIN 51582): 0.05 percent in weight, still usable.
Max. 0.2 percent in weight, change the oil.
3. Air release property LAV (DIN 51381):
LAV new ≤ 5 min. (0.2% at 500 C)
The LAV rises due to oil contamination.
Change the oil in case of fluctuation of pressure and speed variation. Also deterine the LAV value, if
necessary.
4. Damage power stage by the FZG-test (DIN 51354):
The value of the damage power stage reduces with increasing aging of oil.
The extreme pressure (E.P.) additives decompose due to high temperature ( > 1300 C)
Visual check of tooth flanks. Possibly determine the still existing damage power stage.
The following applies to:
T Couplings: Items 1+ 2 EL + RL Converters: Items 1+2+3
VHB Brakes: Items 1+2 R Couplings: Items 1+2+3+4
TP-DTP Couplings: Items 1+2+3 RW-VORECON: Items: 1+2+3+4
S Couplings: Items 1+2+3

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

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

Phone no: +91 040 27173561 Fa
VOITH TURBO
POWERTRANSMISSION
Type: 1210 SVNL 21-22.5

Version No.088 S 000110 to 113
Serial No. 113-00110 to 113
Parts List
VOITH TURBO
POWERTRANSMISSION

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

Fax : +91 40 27171141

SMs
2007


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

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

- drawing item number
- article number
- part designation
- quantity
Storage and preservation
The description refers to the surface protection as far as the surfaces are uncoated
and/or not corrosion-resistant or are of aluminium casting materials.
within India
Parts of the VARIBLE SPEED TURBO COUPLING are wetted with oil (i.e. by
spraying with solvent-free flushing oil) or packed in oil paper or foil during shipment,
which means a 12 months protection against corrossion in case of dry storage
within India.
outside India
In addition, parts of the VARIBLE SPEED TURBO COUPLING are welded in foil.
Dessicant bags in the packing bind part of the humidity. Machine parts packed that
way may also be stored 12 months in a closed, dry and UV-protected room. Do not
cut open or damage the foil.
VOITH TURBO Parts List for VOITH Variable Speed Turbo Coupling
POWER TRANSMISSION 1210 SVNL 21-22.5 -1-
Sectional Drawings : 740 090 130, 740 090 131
Item No. Description Qty.

101/010 Shell 1
101/015 Shell cover 1
101/017 Hex. bolt M16x65 DIN 931, 8.8 48
101/018 Spring washer B16 DIN 137 48
101/020 Bearing ring 1
101/030 Hex. Screw M20x60 DIN 933, 10.9 18
101/040 Spring washer B 20 DIN 137 18
101/050 Cy l.Roller bearing NU 1040 MAC3 1
101/060 Circlip 200x4 DIN 471 1
101/070 Primary wheel 1
101/070/020 Heli coil M24 x 1,5x18 2
101/070/030 Fusible plug M24x1,5 x160º C 2
101/070/040 Flat Sealing ring A24x32 Al. 2
101/080 Hex. Bolt M16x65,8.8 48
101/090 Spring washer B16 DIN137 48
101/100 Primary shaft 1
101/110 Hex. Bolt M30x120 DIN 931, 8.8 20
101/130 Ball bearing retaining ring 1
101/120 O-ring 135x6 1
101/140 Retainer ring 1
101/150 Hex.Screw M12x40 8
101/170 Oil thrower 1
101/180 Cyl.Roller bearing NU 230 MAC3 1
101/190 Slotted round nut KM 29 1
101/200 Lock Washer MB 29 1
101/210 Circlip 150x4 1
101/220 Secondary shaft 1
Voith Turb Pvt. Ltd., P.O. Indtl. Estate, Nacharam,

Hyderabad-500 079. Ph.27173592/3561

101/230 “PA” Angular contact ball bearing 7230, BMPUA 2
101/240 Lubrication ring complete 1
101/250 Cover 2
101/260 Secondary wheel 1
101/310 Cover 1
101/270 Hex. Bolt M30x100-8.8 20
101/295 Spring washer B30 DIN 137 20
101/300 “PA” Angular contact ball bearing 7326 B.TVP.UA 2
101/320 Hex. bolt M12x50 4
101/330 Socket head screw M12x60 DIN 7984, 8.8 5
101/340 Spring washer 13x19x1.2 5
101/360 Fitted key 2
101/500 Isolating disc 1
201/010 Scoop tube housing 1

201/020 Hex. Screw M24x60 DIN 933, 8.8 18
201/030 Cover 1
201/040 Ring 1
201/050 Hex. Screw M10x40 DIN 931, 8.8 4
201/060 Bellows 1
201/100 Cover 1
201/110 Socket head screw M5x12 DIN 7984, 8.8 4
201/120 Set screw M16x20 1
201/130 O-ring 260x5B, DIN 3770 NBR 70 2
201/140/145 Labyrinth cover 2`
201/150 Hex.screw M12x75 DIN 933, 8.8 22

Hyderabad-500 079. Ph.27173592/3561
201/160 Shaft seal 70x105x13 1

201/170 Internal Circlip 310x6 DIN 472 1
201/180 Screw plug AM 16x1.5 3
301/010 Housing lower part 1

301/020 Housing cover 1
301/030 Screw Plug G1 1/4” 2
301/040 Seal ring A42 x 49 2
301/050 Fluid level Indicator 1
301/055 Seal ring 12x18 2
301/080 Cover 1
301/090 Soc.Head Screw M8x20 DIN 912-12.9 10
301/110 Weld neck flange 1
301/120 Flat seal 65PN40(127x77x2) 1
301/140 Weld neck flange 1
301/150 Flat seal 65PN40(127x77x2) 1
301/160 Hex.bolt M16x80 4

301/170 Soc.Head Screw M8x50 DIN 912-10.9 4
301/180 Flange with connector 1
301/190 Flat seal 65PN40(127x77x2) 1
301/200 Orifice plate 1
301/210 Flat seal 65PN40(127x77x2) 1
301/220 Filling pipe 1
301/230 Hex.Screw M12x35 4
301/350 Flange with connector 1

Hyderabad-500 079. Ph.27173592/3561

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

601/020 Spur gear for pump 1
601/030 Roll pin 4x24 DIN 1481 2
701/010 Pump housing 1
701/020 Pump cover 1
701/030 Cover plate 1
701/040 Plain bearing 4
701/060 Drive pinion 1
701/070 Gear pinion 4
701/100 Soc. Head screw M16x220 1
701/130 Spring washer 8.4x13.5x0.5 6
701/140 O-ring 2

Hyderabad-500 079. Ph.27173592/3561
VOITH TURBO
POWERTRANSMISSION
Type: 1210 SVNL 21-22.5

Code :BESCL, BHILAI (BHEL-RANIPET)
Version No.088 S 000110 to 113
Serial No. 113-00110 - 113
Attaching Parts
VOITH TURBO
POWERTRANSMISSION

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

Fax : +91 40 27171141

SMs
2007


Version : 0.00
Printed in India
WEATHERPROOF
TEMPERATURE SWITCHES FLAMEPROOF
SERIES 720 : REMOTE MOUNT TYPE SERIES 730 : DIRECT MOUNT TYPE
● VAPOUR FILLED ● GOOD REPEATABILITY ● S.S. INTERNALS ●
● TAMPERPROOF SETPOINT ADJUSTMENT WITH LOCKING DEVICE ●
● RUGGED DESIGN ●
SERIES 720 WITH STYLE ‘GM’ ENCLOSURE SERIES 730 WITH STYLE ‘GK’ ENCLOSURE
Switzer 720 / 730 Series of temperature switches are Models 721, 723 & 781 have capillary systems for
vapour pressure operated devices, incorporating the remote sensing. Models 731, 733 & 734 have rigid-
mechanisms used in 200 series pressure switches stem thermal systems. Several convenient standard
and 300 series differential pressure switches. These temperature ranges are available. Setpoint is
precision mechanisms are of stainless steel for arduous continuously adjustable over the instrument range. A
atmospheres and high humidity. calibrated scale is provided for approximate switch
setting.
GENERAL SPECIFICATIONS
ENCLOSURE SWITCHING
GM Pressure die cast Aluminium, Element Instrument quality SPCO (SPDT)
weatherproof to IP:66 microswitch (Note 10 & 11)
GA 316 SS, investment cast, weatherproof Differential Fixed or Wideband adjustable
to IP:66 Max. Working Temp. Refer Range Code table
Ambient Temp. (–) 25°C to (+) 60°C (Note 12)
GK & GE Die cast Aluminium, weatherproof to
IP:66 & flameproof to Gr.IIA, IIB or CONNECTION
IIC for H2 GAS. (Note 1) Thermowell Thru' sliding gland – 3/8" NPT(M) for
720 Series; 1/2" NPT(M) for 730 series
Range Several standard ranges between
(–)25 to (+)300°C Electrical For weatherproof enclosures & Gr.IIA,
IIB flameproof enclosures 3/4" ET(F)
Sensor Vapour filled thermal system actuating std. & 1/2" NPT(F) optional; Dual
a 316L SS Bellows entry on request.
Wetted parts 316 SS bulb For Gr.IIC enclosure, 1/2" NPT(F)
alone is available; Dual entry is std.
Repeatability + 1% FSR (Note 4)
Mounting Back panel / wall / Field
Scale Accuracy ± 5% FSR (Note 6) Conformity Generally to BS 6134:1981
Note : For higher ranges Series, 740 / 760 is available with liquid / mercury filled thermal systems.
#0901 TS 720&730 – Rev.1
ORDERING INFORMATION
l l l l l
ENCLOSURE
RANGE CODE & AVAILABILITY
l
Pressure die cast Aluminium weatherproof l
RA NGE RA NGE MWT 721 & 731 &
to IP:66 with Neoprene / Nitrile gasket. G M CODE Deg . C Deg . C 723 & 733 &
781 734
B2C (-) 25 to (+) 35 45 ✓ ✓ ✓ ✓

Investment cast 316 SS weatherproof to
l
H2C (-) 5 to 65 75 ✓ ✓ ✓ ✓
IP:66 with overall size as style GM – for
G A H5C 0 to 70 80 ✓ ✓ ✓ ✓
aggressive atmospheres. Fit for offshore.
J2C 20 to 90 100 ✓ ✓ ✓ ✓
Die cast Aluminium flameproof cum L4C 50 to 120 130 ✓ ✓ ✓ ✓
weatherproof. CMRS approved to Gr.IIA Q4C 100 to 170 180 ✓ ✓ ✓ ✓
& IIB of IS:2148:1981 for flameproofness S5C 150 to 220 230 ✓ ✕ ✓ ✕
& IP:66 for weatherproofness. For Gr.IIC U6C 190 to 260 270 ✓ ✕ ✓ ✕
l
same enclosure with specific certification
G K V7C 230 to 300 310 ✓ ✕ ✓ ✕
at extra cost is available.
Earlier version style “GE” flameproof

enclosure is also available on request. SWITCH CODE, RATING & AVAILABILITY (Note 11)
l
Please consult factory SWITCH DC RATING IN AMPS AVAIL ABIL ITY AVAIL ABIL ITY
AC
AC
CODE RESISTIVE OF SPCO IN OF DPCO IN
INDUCTIVE
RATING
(SPCO) 220V 110V 24V 220V 110V 24V MODEL S MODEL S
MODELS 0 5A 250 / 125V 0.25 0.5 5.0 0.1 0.25 3.0
721, 731
721 & 731
781 & 734
Remote Mount Types 721, 731
D 15A 250 / 125V 0.2 0.4 2.0 0.02 0.03 1.0 721 & 731
781 & 734
Temperature switch with flexible thermal system
comprising of bulb, semi-rigid stem extension, capillary 721, 731
3 15A 250 / 125V N.R. N.R. N.R. N.R. N.R. N.R. 721 & 731
781 & 734
and armour, having close fixed non-adjustable l
switching differential. 7 2 1 3 15A 250 / 125V 0.5 0.5 10.0 0.25 0.25 6.0 723 & 733 723 & 733
721, 731
4 1A 125V N.A. 0.5 0.5 N.A. 0.25 0.25 721 & 731
Same as 721, but with auxiliary mechanism permitting 781 & 734
wide adjustable band of switching diferential without l 3A 250V / 721, 731
5 0.2 0.4 5.0 0.2 0.4 4.0 721 & 731
disturbing the set point (falling temperature). 7 2 3 5A 125V 781 & 734
721, 731
6 0.1A 125V N.A. N.R. 0.1 N.R. N.R. N.A. 721 & 731
A variant of 721, employs twin levers each operating 781 & 734
a SPCO microswitch actuated by a single thermal 721, 731
7 N.R. N.R. N.R. 1.0 N.R. N.R. 0.5 721 & 731
system through a unique linkage thereby providing 781 & 734
two independent adjustable set points, each with its l 721, 731
8 5A 250 / 125V N.A. N.A. 5.0 N.A. N.A. 3.0 721 & 731
own setting scale, spring & switch. 7 8 1 781 & 734
4A 115V 721, 731
9 N.A. N.A. 4.0 N.A. N.A. 2.0 721 & 731
400 Hz. 781 & 734
Direct Mount Types 721, 731
G N.R. N.R. N.R. 1.0 N.R. N.R. 0.25 721 & 731
781 & 734
Similar to 721, but with a rigid stem thermal system l
comprising of bulb and rigid stem. 7 3 1 A N.A. 3.0 10.0 15.0 1.5 6.0 10.0 721 & 731 721 & 731
E 15A 250 / 125V 0.3 0.75 15.0 0.2 0.4 10.0 721 & 731 ---
Similar to 731, but has a wide adjustable band of l F 15A 250 / 125V 0.3 0.75 15.0 0.2 0.4 10.0 721 & 731 ---
switching differential. 7 3 3
Codes 0, 3, D – For General purpose usages. Code 9 – Hermetically sealed, inert gas filled with
Code 4 – With Noble metal contact. Silver alloy contact.
A variant of 731. Provides two independent adjustable Codes 5 – For General purpose with good DC rating. Code G – Hermetically sealed, inert gas filled with
l Codes 6 – With Noble metal contact (Low Rating) Gold plated contact.
setpoints functioning similar to 781 but actuated by a
single rigid stem thermal system.
7 3 4 Code 7 – Environmentally sealed switch with Gold Code A – High DC rated microswitch.
plated contact. Codes E & F – Manual reset switch. Auto change
Code 8 – Environmentally sealed switch with Silver over on rising and falling pressure respectively.
alloy contact. Resetting is Manual.
For DPCO, change switch code to “00”, “22”, “33”, etc., while ordering
THERMAL SYSTEM DATA N.A. – Not Available N.R. – Not Recommended
l
All parts including bellows are of SS except filling tail.

0
CAPILLARY AND MOUNTING
l
Same as above but with sealed protective cover for NH3 The flexible thermal system of Models 721, 723 and 781
service.
A
comprises of 304 SS armoured, 316 SS capillary attached
to the 316 SS sensing bulb via 304 SS semi-rigid stem
FOR 720 SERIES extension, on which a 3/8" NPT(M) compression gland slides
l
E to enable various depths of thermowells to be accommodated.
3 metre capillary 250mm semi rigid stem.
l
The thermal systems of models 731, 733 & 734 comprises a
3 metre capillary 500mm semi rigid stem. F
l
316 SS rigid stem attached to the 316 SS sensing bulb by
G an extension on which a 1/2" NPT(M) compression gland
6 metre capillary 250mm semi rigid stem. slides to accommodate various depths of thermowells.
l
6 metre capillary 500mm semi rigid stem. H

In models 721, 723 & 781, setpoint will be affected by relative
position of head and sensing bulb. i.e., sensing bulb 1 metre
FOR 730 SERIES above / below head will be equal to setpoint shift ±1% of full
scale approx.
250 mm Rigid stem (for all ranges except Q4C) l
400 mm Rigid stem only for Q4C range. T For models 731, 733 & 734 with rigid stem, this does not apply.
SWITCHING DIFFERENTIAL DATA NOTES
1. Gr.IIA & IIB of IS:2148 is equivalent to NEC CL.1, Gr.C & D.

TABLE – A : Fixed on-off differentials for style GM – 721/
731 with 1 SPCO contact switching differentials will be less Gr.IIC of IS:2148 is equivalent to NEC CL.1, DIV.1, Gr.A & B.
than or equal to the published values. For style GK/GE multiply
the listed differential by 1.5 times. 2. Style GM/GA is weatherproof only if all entries and joint faces are
properly sealed. Style GK/GE is weatherproof only if cover
On -o f f Di f f er en t i al i n Deg . C ‘O’ ring is retained in position and proper FLP cable gland is
Ran g e Ran g e used. It is recommended to procure cable glands along with
Mo d el
Co d e Deg . C 3, D, GK /GE instruments to avoid neglect of it while installation.
0 4 5 7, 8 9, G A
6
3. Intrinsic Safety (Exi) — Pressure Switches are classified as simple
B2C (-) 25 to +35 7 4 5 9 12 12 20 electrical apparatus as per BS 5345–6.3.3. Hence Pressure Switches
H2C (-) 5 to +65 4 2 3 6 6 6 10 with GM/GA enclosures may be used in intrinsically safe systems
721 / H5C 0 to 70 4 2 3 6 6 6 18 without certification if energy levels are limited to 1.2V, 0.1A or
731 / J2C 20 to 90 4 2 3 6 6 6 10 25 mW.
L4C 50 to 120 4 2 3 6 6 6 10
Q4C 100 to 170 6 3 4 7 9 9 15 4. Accuracy & Repeatability are one and the same for all blind
temperature switches.
S5C 150 to 220 6 3 4 7 9 9 15
721 U6C 190 to 260 7 4 5 9 12 12 20 5. The instrument is calibrated in the mounting position depicted in
V7C 230 to 300 7 4 5 9 12 12 20 the drawing. Hence mounting in any other direction will cause a
minor range sift.
6. A Temperature switch is a switching device and not a measuring

instrument — eventhough it has a scale to assist setting. For this
TABLE – B : Fixed on-off differentials for style GM – 721/ reason, Test Certificates will not contain individual ON-OFF
731 with 2 SPCO contacts (for DPDT action). Switching switching values at different scale readings. Maximum differential
differentials will be less than or equal to the published values. obtained alone will be declared, besides other specifications.
For style GK/GE multiply the following differentials by 1.2 times.
7. Select working range of the instrument such that the set value lies
On -o f f Di f f er en t i al i n Deg . C in the mid 35% of the range i.e., between 35% and 70% of range
Ran g e Ran g e
span.
Mo d el 33,
Co d e Deg . C 77, 99,
99
00
00 DD, 44
44 55
55 AA
AA 8. For switching differential values please refer respective Range
88 GG
GG
66 Table. Switching differentials furnished are nominal values under
test conditions at mid-scale and will vary with range settings and
B2C (-) 25 to +35 10 5 7 12 16 18 30
operating conditions.
H2C (-) 5 to +65 6 3 4 8 8 9 15
721 / H5C 0 to 70 6 3 4 8 8 9 15 9. On and off settings should not exceed the upper or lower range
731 / J2C 20 to 90 6 3 4 8 8 9 15 span.
L4C 50 to 120 6 3 4 8 8 9 15
Q4C 100 to 170 9 4 5 9 12 13 20 10. DPCO action is achieved by two SPCO switches synchronised to
practical limits i.e., ±2% of FSR. Differential for DPCO contacts
S5C 150 to 220 9 4 5 9 13 13 20 are higher than that of SPCO as force required to actuate the
721 U6C 190 to 260 10 5 7 12 18 18 30 contacts are more. Please refer respective range table for exact
V7C 230 to 300 10 5 7 12 18 18 30 values.
11. Contact life of microswitches are 5 × 105 switching cycles for nominal
load. To quench DC sparks, use diode in parallel with inductance,
ensuring polarity. A ‘R–C’ network is also recommended with
TABLE – C : Wide band adjustable on-off differentials for ‘R’ value in Ohms equal to coil resistance and ‘C’ value in micro
style GM –723 / 733 with SPCO/2SPCO (for DPCO action) Farads equal to holding current in Amps.
contacts. For style GK/GE multiply the lower limit of the listed
wide band adjustable differential values by 1.2 times. 12. All models are suitable for operating within a range of ambient
temperature from (–) 25°C to (+) 60°C. Below 0°C, precautions
Wi d eb an d A d j u s t abl e Sw i t ch i n g should be taken in humid atmospheres to prevent frost formation
Ran g e Ran g e Di f f er en t i al i n Deg . C inside the instrument from jamming the mechanism.
Mo d el
Co d e Deg . C
3 33
33
On models 721, 723 & 781 it is advisable to avoid the condition
B2C (-) 25 to (+) 35 10 -- 30 12 -- 30 where the ambient temperature is within ±5°C of the setpoint.
H2C (-) 5 to (+) 65 10 -- 30 12 -- 30 Under this condition the liquid / vapour phase becomes less well
defined and the switching differential increases. Where this condition
723 / H5C 0 to 70 8 -- 30 10 -- 30
is unavoidable refer to models 740/760 liquid expansion temperature
733 / J2C 20 to 90 10 -- 30 12 -- 30
swtiches or 771–4.
L4C 50 to 120 8 -- 30 10 -- 30
Q4C 100 to 170 8 -- 30 10 -- 30 13. Our standard thermowell for all models is 304SS and threaded
1/2" NPTM with immersion length U = 150mm. Other thermowells
S5C 150 to 220 10 -- 30 10 -- 30
are also available to order. Ask for drawing.
723 U6C 190 to 260 10 -- 30 12 -- 30
V7C 230 to 300 10 -- 30 12 -- 30 14. Accuracy figures are exclusive of test equipment tolerance
on the claimed values.
Switching diffl. for models 781, 734 and Manual reset type micro
switches, please consult factory. 15. All performance data guaranteed ±5%.
MOUNTING DIMENSIONS
WEATHERPROOF ENCLOSURE — STYLE ‘GM’
MODELS 721, 723 & 781 MODELS 731, 733 & 734
FLAMEPROOF ENCLOSURE — STYLE ‘GK’
MODELS 721, 723 & 781 MODELS 731, 733 & 734
L1 — Length of armoured SS capillary (3 Mt. or 6 Mt.) L3 — Length of rigid stem including bulb 250 mm,
L2 — Length of semi rigid stem 250 mm or 500 mm e — Bulb length (80 mm),
(excludes compression gland length) d — Blub dia (12mm).
NOTES: Ä Dim L1, L2 varies depending on armoured capillary length

Ä Use certified weatherproof cable gland for GM enclosure
Ä It is mandatory to use certified flameproof cum weatherproof
cable gland for flameproof enclosures. All dimensions are in mm
Prior notification of changes in specification is impracticable due to continuous development.

#0901 TS 720&730 – Rev.1
FOR SWITZER'S OFFICES IN INDIA

CHECK AT:
http://www.switzerinstrument.com/offices.htm
DIFFERENTIAL PRESSURE
120
INDICATOR — SWITCH
● HIGH STATIC PRESSURE ● UNIQUE MAGNETIC POINTER MOVEMENT ●
● PISTON SENSOR ● D/P OR LEVEL MONITORING ●
FEATURES SWITZER – MID-WEST Differential Unlike ordinary pressure gauge, this can
Pressure Indicator is rugged, designed be supplied with hermetically sealed reed
● Magnetic movement fully isolated
for industrial use to measure the switches to initiate alarm signals or
from pressure media.
differential pressure in a system and system shut down. One or two switches
● Protected against over pressure to
full static pressure rating. indicate directly on a single gauge dial. can be incorporated to provide for low
or high limit alarm or both. SPDT reed
● Line service to 3000 PSI and several
delta P ranges upto 100 PSID A specially designed magnetic movement switches may be connected to open or
allows the instantaneous sensing of both close on either rising or falling pressure.
● Automatic resetting after line surges,
cold starts or system servicing. pressures while completely isolating the Switching may be adjusted from 10% to
gauge function from the pressure 90% of the differential pressure range
● Suitable for measuring the pressure
drop across filters, valves and chamber without the use of mechanical of the instrument. Switch setting is readily
equipments. seals. made through an external adjustment.
GENERAL SPECIFICATION
Range 0 – 100 PSID. See Range table. Case Cast aluminium W / P to IP:65
Maximum Static Pressure 3000 PSIG Max. Process Temp. (–)40 to (+)90°C. Higher for
Gauge Size 150mm dia silicone diaphragm and seals
Process Connection 1/4" FNPT back Switching (optional)
Materials of Wetted Parts Type Hermetically sealed SPDT reed
switch, field adjustable
Sensor 304 SS Piston
Rating 0.25A, 3 Watts, 120V AC / DC
Body & End Fittings Aluminium or 304 SS
Range Spring 304 SS (teflon coating optional) No. of Switches One or two independently
adjustable between 10 – 90% FSR
Magnet Ceramic, resistant to many
chemicals Repeatability ±1%
Accuracy ± 3 – 2 – 3% ascending. ON / OFF Diffl. 5%
± 2 – 1.5 – 2% ascending, Switch Connection Flying leads, 0.5 M long, 26 SWG
available upon request via PG 16 cable gland
STANDARD DIAL RANGES APPLICATIONS CONSTRUCTION
● Hydraulic Systems
P.S.I.D. bar kPa PISTON SEAL
● Diesel Engines “O” RING
MAGNET NUT
0 – 10 0 – 1.0 0 – 100
● Machine Tools
0 – 15 0 – 1.6 0 – 160
● Water Treatment Plants
0 – 20 0 – 2.5 0 – 250
● Power Gas Utilities
0 – 25 0 – 4.0 0 – 400
0 – 30 0 – 6.0 0 – 600 ● Pipe Lines
0 – 50 0 – 7.0 0 – 700 ● Compressors
0 – 60 ● Filters
0 – 75 ● Drying Ovens and Kilns END RANGE SPAN ADJ.
CAP SPRING SCREW
0 – 100 ● Cryogenics
DESIGN AND OPERATION
SWITZER – MID-WEST Differential Pressure Instrument works on the difference Reed Reed
between two pressure (rP) acting on opposite side of a pressure sensor (piston). Switch Switch
Variation in pressure difference will cause the pressure sensor and linear magnet
to move in proportion to this change. A rotary pointer magnet, located in a
separate body cavity follows the linear movement of the pressure sensor magnet
and indicates the differential pressure on the gauge scale.
Switching is achieved by locating reed switches adjacent to the pressure chamber.

The reed switches are activated when the field of the linear magnet interacts at
a preset point with the reed switch armature. Switch actuation point is adjustable Piston or Rotary Magnet Piston or Rotary Magnet
Linear Magnet and Pointer Linear Magnet and Pointer
over the top 80% of the gauge ranges.
ORDERING SPECIFICATIONS
Style 120 – A – 0 – 0 – 0 – 0
Body & Internal Parts
Al. Body & 304 SS internals ––––––––––––––––––––––––––––––––––––––––––––––––––––– A
304 SS body & 304 SS internals ––––––––––––––––––––––––––––––––––––––––––––––––– S
Seals
Buna-N ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 0
Silicon –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 2
Connections
1/4" FNPT back –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 0
1/4" FNPT end (on-line) ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 2
Specials via adaptors (two per instrument) ––––––––––––––––––––––––––––––––––––––––––––––––––––– 9
Options
None –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 0
2" Pipe mounting bracket with U Bolt & Nuts –––––––––––––––––––––––––––––––––––––––––––––––––––––––– F
Panel mounting ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– P
Shatterproof / Toughened Glass ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– G
Electricals
None –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 0
One switch ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– A
Two switches ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– B
One switch with Power relay in Style GM Housing ––––––––––––––––––––––––––––––––––––––––––––––––––––––––– C
Two switches with Power relay in Style GM Housing ––––––––––––––––––––––––––––––––––––––––––––––––––––––– D
Prior notification of changes in specification is impracticable due to continuous development.
Manufactured with
Know-how from
®
FOR SWITZER'S OFFICES IN INDIA Mid-West
Instrument
MICHIGAN, USA
CHECK AT:
http://www.switzerinstrument.com/offices.htm # 40897 DPI – 120

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Customer:BESCL - BHILAI

Version Nos.088 S 000 110 to 113

VARIABLE SPEED TURBO COUPLING

Type: 1210 SVNL 21-22.5

Voith Turbo Pvt. Ltd.

Phone : +91 40 27171440 / 27173592 / 27173561

Service department of the product group variable speed drives

E-mail : Prasad,Chelluboina (Chelluboina.Prasad@Voith.Com)

This instruction manual is protected by copyright. It is neither allowed to translate or

Date of issue : 04/2007

1 Technical Data........................................................................................... .......... 1

1.1 Machine Data........................................................................................... .......... 1

1.2 Operating data.......................................................................................... .......... 3

2 Safety Information.................................................................................... .......... 5

2.1 Meaning of symbols and notes................................................................. .......... 5

2.2 Use in accordance with the regulations.................................................... .......... 5

2.3 Organisational measures ........................................................................ .......... 6

2.4 Selection and qualification of staff........................................................... .......... 6

2.5 Individual operating phases...................................................................... .......... 7

2.6 Warranty .................................................................................................. .......... 8

3 Design and Operation............................................................................... .......... 9

3.1 Design...................................................................................................... .......... 9

3.2 Power transmission.................................................................................. .......... 11

3.3 Speed control........................................................................................... .......... 12

3.4.1 Self-lubrication....................................................................................... .......... 13

3.4.2 Lubrication of external units.................................................................. .......... 13

4 Transport and Storage.............................................................................. .......... 14

4.1 Safetry information................................................................................... .......... 14

4.2 As delivered condition.............................................................................. .......... 15

4.3 Storage and preservation......................................................................... .......... 16

4.4 Unpacking, transportation........................................................................ .......... 17

5.1 Safety information.................................................................................... .......... 22

5.2 Tool and auxiliary means......................................................................... .......... 23

5.3 Mounting the connecting couplings.......................................................... .......... 24

5.4 Setting the machine on foundation........................................................... .......... 25

5.5 Machine alignment................................................................................... .......... 27

5.6 Machine fixing.......................................................................................... .......... 33

5.7 Machine and cooler pipework................................................................... .......... 34

5.8 Connection of electrical instruments........................................................ .......... 37

5.9 Mounting of guards................................................................................... .......... 38

5.10 Fitting a scoop tube actuator.................................................................. .......... 40

6.1 Safety information.................................................................................... .......... 41

6.2 Operation oil fill......................................................................................... .......... 42

6.3 Test run.................................................................................................... .......... 43

7.1 Safety information.................................................................................... .......... 47

7.2 Machine start-up and rundown................................................................. .......... 48

7.3 Machine operation.................................................................................... .......... 49

7.4 Measures in case of tailspin and reverse rotation.................................... .......... 53

7.5 Measures to be taken during stop periods............................................... .......... 54

8 Maintenance and repair........................................................................... .......... 55

8.1 Maintenance measures and intervals....................................................... .......... 55

8.2 Cleaning the double oil filter.................................................................................57

8.3 Inspection of hose lines............................................................................ .......... 59

8.5 Replacement of fusible plugs................................................................... .......... 60

8.6 Cross references...................................................................................... .......... 61

9 Trouble shooting....................................................................................... .......... 62

9.1 Start-up..................................................................................................... .......... 62

9.2 Output speed............................................................................................ .......... 63

9.3 Pressures................................................................................................. .......... 64

9.4 Temperatures........................................................................................... .......... 65

9.5 Quiet running............................................................................................ .......... 66

9.6 Cross references..................................................................................................67

VARIABLE SPEED TURBO COUPLING