900 Power Transmission

900

Power transmission-english

SRP 200 FP - 1800 rpm / 294 kW Torsional Vibration Analysis Project No.: INL-130200-01-02-03-04-05 - Codeword: SCA FERRIES 01-05 - Order No.: 14339821/25/26/27/28

For

SCHOTTEL Rudderpropeller

SRP 200 FP codeword : project No : order No : class : notation :

SCA FERRIES 01-05 INL-130200-01-02-03-04-05 14339821/25/26/27/28 LRoS +A1+LM "inland water ways Ferry"

TVA No

PTK-03-6067

:

Kopie: Hr. Pick SRP Hr. Klein Fr. Navarro Fr. Brohlburg Hr. Hellbach Hr. Kohl Hr. Benke

erstellt / made:

02.02.2015

Berechnungsnummer / calculation ID :

geprüft / checked:

Feldpausch, Alexander Pick, Michael

02.02.2015

Dokumentenversion / document version :

geändert / modified:

-/-

02.02.2015

PTK-03-6067 1.0 page: 1/9


Important Notes: This Torsional-vibration-Calculation for the propulsion system shown next page corresponds to the latest state-of-the-art in vibration technology. The technical data of those parts of this system, that are not SCHOTTEL products were taken over from manufacturers manuals or the responsible project departments. The calculation is only valid for the actually calculated and herewith described conditions. Any torsional problem caused by the motor governor is not covered by this calculation. The responsibility of this calculation can only be taken over for the SCHOTTEL products of this plant.

Any unauthorised deviation to the calculated layout of the drive line leads to the loss of any guarantee or warranty. Technical data referring to Torsional-Vibration-Calculation - service speed minimum service speed (clutch engaged!) nominal service speed (max. service speed)

nL = nN =

650 rpm 1800 rpm

- additional mass no additional mass necessary - remarks/conclusions: -

-

misfiring condition of engine is calculated for 1 cylinder active for 25%. SCHOTTEL does not recommend running under misfiring conditions. based on technical data we got from shipyard, engine supplier and sub supplier the following analysis shows, that the vibration torque is within the limits of the manufacturer. Under consideration of these suppositions continuous running is without harmful torsional vibrations at the SCHOTTEL gears and elastic coupling.

- calculations are carried out for: -

-

motor excitation under normal conditions motor excitation under misfiring conditions propeller excitation at max. power consumption (propeller) propeller excitation is calculated as a percentage of the actual mean torque with 4 % for blade and 2 % for double blade frequency. cardan shaft excitation

Conclusions: Under consideration of the above mentioned suppositions continuous operating is without harmful torsional vibrations at the SCHOTTEL gears, the shafts and the elastic coupling.

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system component data

systemno.: 1-9

name: diesel engine

9 10-11

flywheel elastic coupling

17-19

clutch

12-13

cardan shaft

14-15

elastic coupling

20-25

rudderpropeller

16

propeller

manufacturer/technical data: manufacturer: type: power : at rated speed : J: manufacturer : type : TkN: PkV: manufacturer : type : manufacturer : type : Lz: β: manufacturer : type : TkN: PkV: manufacturer : type : reduction : ∅: Jair : Jwater : z:

VOLVO PENTA D13 294 kW 1800 rpm 2,21 kgm² VULKAN Vulastik-L 2611 3250 Nm 609 W SCHOTTEL K 200 GEWES 68 1500 mm 3,4° VULKAN Vulkardan-L 4514 3150 Nm 320 W SCHOTTEL SRP 200 FP i = 3,367 PAL = 1700 mm 1100 mm 9,6 kgm² 13,5 kgm² 5

nominal operation point: SRP input:

P n T

= 294 kW = 1800 rpm = 1560 Nm

gear:

i n T

= 3,367 = 535 rpm = 5252 Nm

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TVA input data for "DRESP 12.0.4" ( all values are not reduced ! ) DRESP vibration model 'SCA FERRIES 01-05' ========================================= Masses Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

erstellt / made:

Identifier damper front cylinder 1 cylinder 2 cylinder 3 cylinder 4 cylinder 5 cylinder 6 flyhweel 14" J1 VULKAN J2 VULKAN 1/2 cardan shaft 1/2 cardan shaft J1 VULKAN J2 VULKAN propeller + water K 200 inner part K 200 shaft flange flange upper pinion upper wheel lower pinion lower wheel propeller shaft

mass moment of inertia [kgm^2] 0.296 0.01 0.153 0.123 0.153 0.153 0.123 0.153 2.21 0.32 0.11 0.05045 0.05045 1.59 0.64 13.5 1.601 0.5764 0.018 0.0078 0.07 0.114464 0.049056 0.899 3.9E-4

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Couplings Number

From mass

To mass

Identifier

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

2 3 4 5 6 7 8 9 10 11

11 12 13 14 15

11 19 12 13 14

17 12 13 14 15

16 17 18

15 25 17

20 16 18

19 20 21 22

18 20 21 22

19 21 22 23

23 24

23 24

24 25

damper crank crank crank crank crank crank crank rigid link Vulastik-L 2611 rigid link rigid link cardan shaft rigid link Vulkardan-L 4514 rigid link rigid link clutch engaged output shaft pinion shaft upper gear vertical shaft PAL 1700 lower gear propeller shaft

erstellt / made:

Torsional rigidity [Nm/rad] 1.0E10 6786000.0 3939000.0 3939000.0 4014000.0 3939000.0 3939000.0 6786000.0 1.0E9 11500.0

Damping

Gear ratio [-]

0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.0 0.09

Type of Damping [0=D,1=k,2=psi] 0 0 0 0 0 0 0 0 0 0

1.0E9 1.0E9 120000.0 1.0E9 13000.0

0.0 0.0 0.015 0.0 0.13

0 0 0 0 0

1.0 1.0 1.0 1.0 1.0

1.0E9 1.0E9 1.0E8

0.0 0.0 0.01

0 0 0

1.0 1.0 1.0

576980.0 1973700.0 8025700.0 238750.0

0.01 0.01 0.04 0.01

0 0 0 0

1.0 1.0 1.381 1.0

3.8147E7 4954200.0

0.04 0.01

0 0

2.438 1.0

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1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

PTK-03-6067 1.0 page: 5/9


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normal upper gear:

normal lower gear

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misfiring upper gear:

misfiring lower gear:

erstellt / made:

02.02.2015


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12

11

10

9

8

7

6

5

4

3

2

1

1500

A

H

H

4,5

(57 Nm)

Y

2

3

1

9

78 3

6

11,12

+0,50 0

10,12 G

G

H7

110

180

92

B

Schwerpunkt Center of gravity

7

F

F

12

A

ca.697

Schottabdichtung entsprechend der Lage der Schottwand auf der Kardanwelle verschieben.

Ueberall dort, wo eine Gefaehrdung von Menschen und Material durch rotierende Teile moeglich ist, sind vom Anwender und/ oder Betreiber entsprechende Sicherheitsvorkehrungen zu treffen. Der Einbau darf nur durch fachkundiges Personal durchgefuehrt werden!

Bulkhead seal can be moves on the cardan shaft on the suitable position.

E

Darstellung ohne Transportsicherung Representation without transportsaftey

8x45°(=360°) 45°

D

8x 14

Where danger to people or material can be caused by rotating parts, a safety device has to be installed by the user and / or operator. The installation or parts of it is only allowed by specialists!

A-A

B B12

Y

Transporthalterung Pos. 9-12 bei Endmontage entfernen! 1 Removal transportation device Pos.9-12 before final installation.

Einbauzustand Mountingstate

2

Dichtungen Pos.7 gemaess Einzelheit Y montiert. Sealings Pos.7 mounted according detail Y.

10°

6

22,5°

D

1

Dichtflaeche vor Endmontage der Dichtringe Pos.7 mit Petroleum oder aehnlichem Mittel gereinigt! Nach Montage der Dichtringe, Dichtung ueber Schmiernippel Pos.7 mit Fett L2 ID-NR:1075352 abgeschmiert!

2

7

Before final mounting, contact face for V-seals cleaned with petroleum or similar fluid! After final installation of the V-seals, space between V-seals greased with grease L2 ID-No:1075352!

7

C

0

C

E

15 5

,5

282 h7

blanke Flächen mit TECTYL Nr.846 ID-N^r. 1039098 konservieren! bright areas conserved with TECTYL Nr. 846 IDNo. 103908!

Abnahmepruefzeugnis DIN EN 10204:2005-01-3.2 nach den gueltigen Vorschriften der geforderten Schiffsklassifikationsgesellschaft Inspection certificate acc. to DIN EN 10204:2005-01-3.2 complying with regulations of stipulated ship classification society

Reservedichtung reserve seal

Reservedichtung reserve seal

L NTIA

B

FIDE CON 350

D

300

Pos.9-12

D (2 : 1)

330

Transportsicherung Transport saftey

110

8

Dieser Entwurf ist geistiges Eigentum der SCHOTTEL GmbH

Schutzvermerk DIN ISO 16016 beachten

Werkstueckkanten DIN ISO 13715

Allgemeintoleranz DIN ISO 2768-mK Schweisskonstr. DIN EN ISO 13920-CF Tolerierung DIN EN ISO 8015 Oberflaechenangaben DIN EN ISO 1302

-0.3

Projektionsmethode 1 DIN ISO 128-30 +0.8

Name Datum Bearb. 06.01.2015 NoetzelK Gepr. 07.01.2015 PickM AV 09.01.2015 LangFW Norm 18.02.2015 MalewskiD Abt.

A

1 Zeichnung & Stückliste kpl. überarbeitet. Positionsnummern geändert und ergänzt! Drawing and Partlist cpl. revised. Amended and completed item numbers. 12

11

10

9

8

7

6

5

4

001

15/0392

09.02.2015

NoetzelK

000

0000

06.01.2015

NoetzelK

Zust. Aenderung Datum

3

Name

SCHOTTEL GmbH Mainzer Strasse 99 D-56322 Spay/Rhein Urspr.:

B12

282 Maß

h7

CAD-ZEICHNUNG Manuelle Aenderung verboten !

110,035 110 14,33 14,15 282 281,948

Typ: SRP 200 FP Gewicht: 131.00 kg

A

Benennung:

Gelenkwelle kpl. 45-68 Flansch D 180 LZ1500 Cardan Shaft cpl. 45-68

Zeichnungs-Nr.

1208393 Ers. f.:

2

8x 14

Massstab: 1:2.5 Werkstoff: Rohteil-Nr.: Modell-Nr.:

0,035 0 0,33 0,15 0 -0,052 Passung

H7

B

Index: 001

Format

Bl.Nr.: 1 von 1 Ers. d.:

1

1

Technical Description

Edition 2007

Mounting, maintenance and repair of propshafts with flanged universal joints 1. Recommendations Assembly, disassembly, maintenance and repair of propshafts should be performed only by qualified personnel. In addition, for repair work we recommend the use of original spare parts. Our propshafts are supplied ready for installation and operation. All are lubricated, base painted and the matching surfaces of the flanges are protected by an anticorrosion-oil-film, which must be removed before assembling the propshaft into the powertrain. The propshafts have been dynamically balanced to ensure perfect smooth running. The balance plates attached to the drive shaft tubes or the joint drivers must not be removed as they are essential for the vibration-free running of the propshaft. For the same reason, the joints must not be exchanged with one another. When a propshaft is being installed care must be taken to ensure that the engraved indicating arrows coincide so that the two joints are located within one plane, as required for perfect motion. Fig. 1

yoke

Marking arrows

If the rotating propshaft might be dangerous for its environment, safety-means should be provided. This applies especially to propshafts rotating at high speed. The propshaft should be set-up according to the installation instructions issued by the final manufacturer. For safety reasons, propshafts used in hazardous environments should be suitably guarded. High-speed propshafts should be guarded by safety bands to avoid damage in the event of shaft release or fracture. The relevant national regulations concerning industrial safety and protective efficiency are to be observed. Dust and dirt adhering to the propshaft may deteriorate the balancing quality. Additionally, oily dirt may ignite on hot surfaces of the propshaft and this dirt should be removed on a regular basis. Under normal conditions the surface-temperature of propshafts should not exceed 70 centigrade (158°F). However, under unfavourable conditions the temperature may raise above 70 centigrade (158°F). In such cases please contact our application-engineers for discussing means to lower the temperature. During transport and storage, the propshafts should be handled carefully and be protected against impacts and shocks in order to guarantee the balance quality. Propshafts should preferably be transported and stored horizontally. Any neglect of these instructions may lead to impairment of operation or a reduction in functional reliability. CAUTION – Propshafts with length compensation may become separated at the slip section causing damage to propshaft components and possible injury. Also universal joints may tilt in handling possibly causing injury. Propshafts should be stored in a dry atmosphere preferably in horizontal position and secured from falling over or rolling. Gelenkwellenwerk Stadtilm GmbH • Weimarische Str. 62 • D-99326 Stadtilm • Phone +49 3629 6400 • Fax +49 3629 800002 • [email protected] • www.gewes.de

Einbau und Wartung englisch – Edition 2007

Page 1 of 5

2. Assembly Before the propshaft is installed, the faces of the two flanges (shaft flange and connecting flange) are to be cleaned, i.e. the faces and centring surface must be free of burrs, dirt, paint and grease. The axial and radial run out tolerances admissible for the companion flange are to be maintained, otherwise the correct running of the propshaft may be affected (Fig. 2 and Table 1). Fig. 2 Recommended radial run out K R

Table 1 Speed rpm Up to 500 500 to 3000 More than 3000

tolerance for d

Radial Run out KR

axial Run out KS

h8

0,15

0,18/100

h7

0,08

0,10/100

h6

0,05

0,07/100

(KS is in relation to Ø100 mm)

Recommended axial run out K S

Both flanges are connected by means of hexagon bolts according or similar to ISO 4014 of property class 10.9 and hexagon nuts according to ISO 7042-V of property class 10. Not all types of our propshafts allow inserting the hexagon bolts from the joint end. Particular attention should be given to tighten the flange connecting bolts in order to achieve the necessary frictional torque transfer. Suitable wrenches are to be used. The specified tightening torques are provided in our latest catalogue.

3. Maintenance Propshafts without grease nipples are greased for life and therefore require no further lubrication. If high pressure equipment is used for cleaning, it is important not to direct the jet directly onto the seal. For propshafts fitted with a tape red grease nipple (acc. to DIN 71412) or flat grease nipple (acc. to DIN 3404) it is possible to lubricate the joints with a grease gun (see Fig. 3). Fig. 3 Joint relubrication

spline relubrication

The grease nipples must be cleaned before a grease gun is applied. The 4 bearings of each joint are lubricated by one central grease nipple. Gelenkwellenwerk Stadtilm GmbH • Weimarische Str. 62 • D-99326 Stadtilm • Phone +49 3629 6400 • Fax +49 3629 800002 • [email protected] • www.gewes.de


Page 2 of 5

Complete lubrication is achieved when grease can be observed coming from the bearing seals. For shafts with regreaseable shaft length compensation, 10 - 40 g of grease should be sufficient depending on shaft size. Grease guns must be operated smoothly, at pressures not exceeding 2 MPa to prevent any damage to the seals. Regreasing is necessary after cleaning with high pressure equipment. It is important not to direct the jet directly onto the seal. Suitable lubricants recommended: Lithium complex greases of specification KP 1-2 N-30 or KP 2 N-20 DIN 51502 with EP additives. No greases containing MoS2 or other solid lubricant additives to be used for the joint bearings as well as sliding part. When the application temperature limits exceed the normal range of +80°C to -25°C (+176oF to -13oF), special-purpose greases of the above- mentioned specification should be used. For general applications, the following directions are recommended: Propshafts employed in:

Maintenance interval

Road motor vehicles Off-road motor vehicles Off-road motor vehicles in building sites Rail vehicles Stationary plant Marine drive lines

50,000 km (31,000 miles) or 1 year 30,000 km (18,500 miles) or 1 year 10,000 km (6,200 miles) or 250 hours 3,000 hours or ½ year 500 hours 1,500 hours or ½ year.

Shorter maintenance intervals will be required where the propshafts are operated in extremely adverse conditions. The maintenance intervals of the propshafts in special applications are to be agreed with the final customer (OEM). Propshafts taken out of pro-longed storage (6 months and more) should be lubricated before being installed.

4. Repair Only qualified and experienced technicians should repair or assemble propshafts as poor workmanship and improper procedures may cause malfunction due to excessive wear, heat, or vibration. The propshafts can be reconditioned with the aid of simple auxiliary tools, as the joints can be completely disassembled and the length-compensating attachment can be exchanged. The principal points of wear are: Joint bearing: ¾ Visual inspection: Perceptible play in the bearings, damaged sealings ¾ After disassembling: Wear marks and indications of pitting on the bearing surfaces; damaged rollers; worn sealing, Sliding part: ¾ Visual inspection: Perceptible play permitting twisting and/or tilting; damaged sealing; damaged sealing area of the hub (if coated then coated with RILSAN®) ¾ After disassembling: Indications of pitting at profile flanks and at the head periphery; damaged sealings, damaged coating of the hub/ splined shaft, corrosion. Gelenkwellenwerk Stadtilm GmbH • Weimarische Str. 62 • D-99326 Stadtilm • Phone +49 3629 6400 • Fax +49 3629 800002 • [email protected] • www.gewes.de


Page 3 of 5

4.1. Replacing the journal crosses Pay attention to clean surroundings to avoid any dirt or dust intruding in the bearings to be assembled, and to a smooth surface of the bore for the bearing.

4.1.1. Closed bearing eye Because the bearing bushes cannot be removed completely out of the bearing eye (because of interference with the cross and claw), in a first step the two opposite bearing bushes of the fork of the weld yoke will be removed half way. Thereafter by applying the ring as shown in fig. 4 or by inserting of discs the complete removal of the bearing bushes can be done. At this disassembly some damage at the bushing or the plastic disc at the bottom of the bushing may occur. In this case these parts have to be replaced anyway. If you still cannot take off the bearing bush by hand after pressing it out half way, you may tap the yoke ear lightly for loosening the bearing bushing. The disassembly of the two bearing bushes of the flange yoke follows the same procedure as described above. (Fig. 5) Fig. 4

Fig. 5 Press

flange

Press sleeve

adaptor ring flange journal cross

sleeve

protection cover Auxiliary tool

Auxiliary tool

The bearing bush must not be canted while it is being pressed in, it should be seated firmly in the bore of the flange yoke. The locking rings must fit snugly into the ring grooves provided. To avoid any deformation, the flange yoke should be supported during the push-in operation, if possible. Any adjustment necessary to take-up any play in the joints or lack of concentricity should be carried out at the same time (permissible tolerance +/- 0.05 mm). Play and press fit, are compensated for by using locking rings of different thickness. The joint must be smooth moveable to avoid too much friction and heat during operation, by which the joint may fail prematurely.

4.1.2. Split bearing eye ( bolted yoke) On joints with split bearing eye bores the bearing caps should be slackened to allow removal of the cap. After the 2 bearing caps have been removed, the spider, including the bearing sleeves, can be separated from the yokes. Note! Bearing caps and yokes are in pairs and therefore must not be interchanged or mounted in a different position during reassembly (you may mark them differently before disassembly for this purpose!). The complete cross will be assembled by inserting it in the yokes and putting the caps on the yokes. The caps have to be tightened to the yokes with new proper screws applying the prescribed torque. Gelenkwellenwerk Stadtilm GmbH • Weimarische Str. 62 • D-99326 Stadtilm • Phone +49 3629 6400 • Fax +49 3629 800002 • [email protected] • www.gewes.de


Page 4 of 5

To achieve the right backlash you may either use discs of different thickness at the bottom of the bearing bush ring segments of different thickness, which keep the cross concentric to the 2 claws. The joint must be smooth moveable to avoid too much friction and heat during operation, by which the joint may fail prematurely.

4.2. Slip assembly Disassembling and remounting entails experience and craftsmanship besides appropriate equipment, especially in welding and balancing. In a first step the tube and the profiled part have to be separated by removing the weld seam on a lathe (Fig. 6). The profiled hub and shaft always have to be replaced together, because these parts are matched individually as a unit. Before welding the tube and profiled part make sure a perfect alignment of both parts, e.g. by providing an interference fit. Fig. 6

tool Splined part

centering tube

The radial tolerance of the alignment should be within 0.5 mm. After the welding operation this components (tube and profiled part) are put together with the other profiled part. At this step it has to be observed, that the inner yokes have to be in the same plane at a radial tolerance of max. 3°. Thereafter the complete propshaft has to be straightened at a max. radial run out of 0.5 mm.

4.3. Balancing Balancing too entails craftsmanship, experience and suitable equipment. If not available, you may use our workshop or ask us for an authorized workshop near your site. After a repair (replacement of crosses or slip assembly) generally propshaft running at more than 500 rpm should be balanced. Unbalanced propshafts may cause vibrations, which jeopardize operators and can damage or destroy the propshaft itself and adjacent components of the whole powertrain. The balancing quality has been regulated by DIN ISO 1940 standard: Balancing quality G 40 for propshafts for general applications Balancing quality G 16 for propshafts for special applications

Gelenkwellenwerk Stadtilm GmbH Weimarische Str. 62 D-99326 Stadtilm Germany / Deutschland Telefon: +49 3629 640 0 Telefax: +49 3629 80 00 02 Internet: www.gewes.de E-Mail: [email protected] Gelenkwellenwerk Stadtilm GmbH • Weimarische Str. 62 • D-99326 Stadtilm • Phone +49 3629 6400 • Fax +49 3629 800002 • [email protected] • www.gewes.de


Page 5 of 5

SHAFTING INSTALLATION INSTRUCTION

SCHOTTEL GmbH Mainzer Straße 99 56322 Spay GERMANY Phone: Fax: mailto: www.schottel.de

14/1382

+49 26 28 / 61-0 +49 26 28 / 61-300 [email protected]

Table of Contents 1 1.1 1.2 1.3 1.4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About these Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scope of documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copyrights and industrial property rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symbols and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 5 5 5 6

2 2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.3 2.4 2.5 2.6

Safety and Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition of the terms used for those with positions of responsibility . . . . . . . . . . . Principles of work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instructions for transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instructions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instructions for alignment and checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instructions for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety regulations for the handling of operating materials . . . . . . . . . . . . . . . . . . . . Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use of original spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 9 9 9 10 10 11 11 12 13 13 13

3 3.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Structure and mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 4.1 4.2 4.3

Transportation and delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transportation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condition on delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection after delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 5.1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Storage methods and storage periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6 6.1 6.2 6.3 6.4 6.4.1 6.4.2 6.5 6.6 6.7 6.8 6.9 6.10 6.11

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Required working conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Documentation of measures; record sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alignment proposal for universal shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Types of bearing bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of the intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alignment of the intermediate shaft and bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alignment of the cardan shaft deflection angles using pointers . . . . . . . . . . . . . . . Installation of the cardan shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of the bulkhead seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of other shafting sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TTD/Gö Shaft Installation Instructions 1191153 14/1382 en

17 17 17 17

21 21 21 22 23 23 24 25 25 26 28 30 31 31

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6.12

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Checking the shafting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

7

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8 8.1

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35


1

Introduction

1.1

About these Instructions

These Instructions describe the installation of SCHOTTEL shafting systems. Shafting systems transfer the drive power from the engine/propulsion motor to the propulsion unit; it comprises various subassemblies, e.g. cardan shaft and intermediate shaft. SCHOTTEL GmbH's shafting systems are available in different versions and supplied as part of the overall system. See the SCHOTTEL GmbH installation documents supplied for the relevant versions. These Instructions are aimed at those who prepare, assemble, align, adjust and check shafting for installation, as well as hand shafting over to the operator or shipyard. Those authorised to carry out the work must fulfil the SCHOTTEL GmbH requirements; see 2.1 “Definition of the terms used for those with positions of responsibility” section. Staff are to have read and understood these Instructions thoroughly before commencing any work. The basic prerequisite for work safety is the observance of all safety instructions and other instructions provided.

1.2

Scope of documentation

●

Installation Drawing

●

Individual drawings of the sub-assemblies

●

Alignment Data Sheet for cardan shaft alignment

●

Installation and alignment record sheets (drawn up by the person concerned)

●

Other applicable SCHOTTEL specifications (depending on the other sub-assemblies to be installed)

These Instructions describe all measures necessary for safe installation and the proper alignment of shafting for the variants available at the time of printing. The SCHOTTEL Service Department is to be consulted about special customised designs prior to commencement of work. For SCHOTTEL GmbH contact details, see page 2. Installation instructions are supplied for every installation. These are to be kept safe and available for staff at all times. If a set of installation instructions are no longer legible or are mislaid, a new copy is to be obtained from the SCHOTTEL Service Department immediately. Please contact the SCHOTTEL Service Department in the case of any queries, suggestions for improvement, or errors.

1.3

Copyrights and industrial property rights

These Instructions or excerpts thereof may only be duplicated, translated or made available to third parties with the express written consent of SCHOTTEL GmbH.


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1.4

Symbols and diagrams

Warning notices Warning notices are set apart from the rest of the text in these Operating Instructions. They are marked in colour and introduced with a symbol and keywords that highlight the extent of the risk or hazard. It is essential that warning notices are heeded and handled with great care to prevent accidents, personal injuries and material damage from occurring.

DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE Indicates actions which may result in material damage.

KEYWORD Cause of the danger Consequences of the danger ▶ Measures to avert the danger Tips and recommendations

i

INFORMATION

Instructions and information for efficient and trouble-free operation.

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Diagrams References to illustrations are written in brackets in the text, e. g. (1/3). The first number refers to the illustration number; the second number is the item number in the illustration. For example: (1/3) means figure 1, item 3. All illustrations are schematic diagrams and do not make any claim to completeness. Lists and grouped safety instructions ●

Items in a list and grouped safety instructions are introduced with a bullet point. The order in which they appear does not represent their order of importance.

Instructions If instructions consist of several steps to be carried out in a sequence, these steps are numbered and listed chronologically in the specified order. For example: 1. Switch off the propulsion unit and make sure it cannot be started up unintentionally. 2. Place a suitable collecting basin underneath the pressure filter.

▶▶ This symbol refers to continuation on the next page.


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2

Safety and Environmental Protection

2.1

Definition of the terms used for those with positions of responsibility

Shipyard The shipyard is the natural or legal person that hands over the shafting to the operator following installation in the respective vessel. The shipyard is to ensure that the necessary handover records and acceptance documents are complete and in a legible condition when the vessel is handed over to the operator. Furthermore, the shipyard is responsible for the complete creation and handover of the necessary installation record sheets to SCHOTTEL GmbH. Operator The operator is the natural or legal person that uses the shafting as part of the entire propulsion system supplied by SCHOTTEL GmbH, or on whose order the shafting is used. Authorised person Authorised persons are service technicians from the manufacturing company or those who fulfil the following requirements: ●

Completed a vocational qualification which clearly demonstrates the professional knowledge acquired. The basis of verification should be in the form of vocational qualifications or comparable certificates.

●

Professional experience that requires that the authorised person has had practice in carrying out installation and alignment work for a verifiable period. In the process, the authorised person has learned about the required tools and testing equipment, as well as the risks resulting from necessary actions and the working environment.

●

A current professional occupation within the field of the upcoming inspection of the shafting and an appropriate advanced training qualification are absolutely essential. The authorised person has to have experience in performing the upcoming inspection/testing or similar. Furthermore, the authorised person must have state-of-the-art knowledge regarding the shafting to be inspected/tested and the risks involved.

2.2

Principles of work safety

2.2.1

General safety instructions

●

The environmental and occupational safety regulations that apply at the site of operation are to be observed. The operator's operating instructions and shipyard safety regulations are to be obtained prior to commencing work and observed during the work required.

●

The shipyard is to be consulted before components are moved on a docked vessel. Introducing heavy loads may cause the vessel to become unstable in the dock.

●

The working area is to be taken into account during all work to be performed. Work performed in parallel within this area, e.g. conveying with lifting gear, may put others at risk due to a lack of proper consultation.

●

Any malfunctions or defects to the shafting sub-assemblies which may affect safety are to be remedied immediately. If this is not possible, the SCHOTTEL Service Department is to be consulted immediately.

●

Safety and monitoring devices must not be modified or removed.

●

The direct supervisor is to be informed in the event of injuries occurring, however serious or minor.

●

Installation work on electrical components may only be carried out if the propulsion system is voltage-free.

●

Personal protective equipment must be worn.

●

Make sure that walked-on surfaces in the working area are kept free of oil and grease.


9/40

●

Smoking is prohibited in operating areas.

●

Before connecting the shafting to the engine/propulsion motor and propulsion unit make sure that they cannot be started up unintentionally.

2.2.2

Safety instructions for transportation

●

Shipyard regulations regarding lifting operations are to be observed.

●

Always observe the dimensions and weights of the individual components.

●

The individual components are to be attached, fastened and packaged in such a way that damage in transit can be ruled out.

●

Only use lifting gear (e.g. crane or forklift truck) and slings (e.g. chains, ropes, and crossbars) that have been checked and approved for the weight of the individual components and are in perfect condition.

●

The operating and safety instructions for the lifting gear and slings are to be observed.

●

Lifting gear and slings may only be used by persons trained and authorised to carry out this type of work.

●

Only attach the shafting and its sub-assemblies using the designated suspension points. If necessary, please enquire about attachment options in the SCHOTTEL Service Department.

●

An adequate danger zone is to be designated prior to transportation work.

●

At least one other person has to be present when lifting, conveying and setting down the components. The load is to be constantly watched when being lifted, conveyed or set down.

●

Before transportation, the signaller and the slinger are to ensure proper communication by using agreed hand signals, equipment or by radio.

●

Never stand or walk under suspended loads.

●

The load is to be transported as close to the ground as possible and prevented from swinging.

●

If the load is set in motion, e.g. due to strong winds, it is to be secured using a rope.

2.2.3

Safety instructions for installation

●

Check the delivery is complete and in perfect order before installation.

●

Make sure there are safety and warning labels attached to the shafting sub-assemblies and that these are kept clean and in a legible state.

●

Malfunctions within the working area that affect safety are to be reported to the responsible body immediately. Stop all work until the malfunction has been remedied.

●

Before commencing work make sure an adequate safety zone has been defined and marked out around the working area. If this safety zone is failed to be observed by staff not involved in the installation process, work is to be stopped until this safety zone is properly re-established.

●

Before any welding, flame cutting and grinding work is carried out, the shafting, its sub-assemblies and the surrounding area are to be cleaned to remove any combustible substances. There is a risk of fire and explosion for this kind of work. Welding, flame cutting and grinding work may only be carried out if this has been expressly approved by a supervisor.

●

During welding work on or around the shafting make sure the earth terminal is attached in the immediate vicinity of the weld to prevent currents from accidentally flowing across the bearings.

●

Make sure shaft seals and track rings are protected against heat, weld spatters and swarf, by attaching suitable covers.

●

Only carry out installation work with suitable tools.

●

Never use defective tools; such tools are to be replaced.

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●

Depending on type, fastening screws and bolts are to be tightened with the specified torque and secured to prevent them from loosening. Refer to the installation documents for torques and the type of screw/bolt retention needed.

●

Make sure thread locker, sealant, oil, acid, cleaning agents or preservatives do not come into contact with skin or eyes.

●

If an accident occurs despite all safety precautions being taken, perform first aid immediately and call a doctor.

●

Fuels or other highly combustible substances must not be used to clean the propulsion system or its parts.

●

Make sure shaft seals and track rings do not become damaged during installation work.

●

Shaft seals and track rings must not be painted over.

●

Installation is to be documented on the designated form; see 6.3 “Documentation of measures; record sheets” section.

●

When work is interrupted, the shafting and its sub-assemblies are to be secured to prevent them from moving unintentionally and a third party being put at any kind of risk. Open sub-assemblies are to be covered to stop foreign substances from entering them.

2.2.4

Safety instructions for alignment and checking

●

Record the alignment and checking of the shafting in the designated documents.

●

Make sure the specified adjustment values and tolerances for aligning and checking the shafting are adhered to. In case of non-observance of the specified tolerances always consult the SCHOTTEL Service Department.

●

Never use defective inspection, testing and adjustment equipment; such equipment is to be replaced.

●

If inadmissible deviations are established during checks, the error is to be confirmed by rechecking these before changing the setting.

2.2.5

Safety instructions for start-up

●

Shafting systems may only be put into operation if they are in perfect, technical working order.

●

Shafting is to be taken out of service immediately in the event of malfunctions. The malfunction is to be rectified immediately.

●

Make sure installation and alignment record sheets are available for the start-up and provided for the SCHOTTEL GmbH staff involved in the start-up.

●

An adequate danger zone is to be designated around the shafting prior to start-up. No-one is to enter or remain in this danger zone during start-up.

●

Moving parts of the shafting are to be covered by a protective device. If this is not included in SCHOTTEL GmbH's scope of delivery this is to be installed by the shipyard.

●

Any parts connected to the shafting (e.g. engine/propulsion motor, propulsion unit and hydraulic system) also have to be ready for the start-up. This is to be communicated and confirmed with the workers and companies involved. The shipyard and operator are always to be informed about start-up so that malfunctions and risks arising from parallel work processes can be ruled out.


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2.3

Safety regulations for the handling of operating materials

●

The manufacturer's specifications regarding the operating materials to be used must be observed.

●

Operating materials may only be stored in the designated containers. It is absolutely imperative that these containers are not mixed up with ones used for foodstuffs, i.e. beverages. The storing of operating materials in the vicinity of foodstuffs is prohibited.

●

Smoking, eating and drinking is prohibited when working with operating materials.

●

Avoid contact with skin, eyes and clothes.

●

If operating materials get into the eyes, rinse out immediately with plenty of clean water. Call a doctor immediately if the eyes become irritated.

●

If oil is swallowed, do not induce vomiting; instead, call a doctor immediately and keep the label handy.

●

After inhaling oil fumes or vapours get plenty of fresh air.

●

If any operating materials come into contact with the skin wash off immediately both thoroughly and repeatedly with water and soap.

●

Remove any oil-soaked clothes immediately.

●

Avoid spilling operating materials.

●

Bind, absorb and dispose of any spilt operating materials immediately.

●

Watch out for hot system parts within the working area. Oil or grease may ignite on hot components.

●

Contaminated or drained operating materials must not be reused.

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2.4

Emissions

During installation, risks may arise in the various work stages from the emissions explained in the following. The measures taken to protect staff do not replace the national occupational health and safety regulations applicable in the country of operation, or the safety regulations of the shipyard and operator. Generated noise levels When the shafting is used as intended, a noise level of 85 dB(A) may be exceeded within its operating area. Ear protectors are to be worn. Start-ups may only be carried out if all specified noise control devices have been installed and closed properly. Exhaust fumes Combustion engines consume oxygen and release carbon dioxide, carbon monoxide and other poisonous gases. Leaks in the exhaust system can be life threatening. ●

Only start up combustion engines in closed rooms, if there is a sufficient air supply available.

Heat Exhaust fumes or exhaust system components (e.g. exhaust pipes or flues) can be so hot that body contact may result in skin burns; materials that get too close may also get burnt or scorched. ●

Never touch hot exhaust pipes/flues.

●

Keep combustible materials away from exhaust pipes/flues.

●

Apply first aid immediately in the event of burns.

●

Take fire fighting action immediately in the event of burning materials.

2.5

Use of original spare parts

Original spare parts and accessories have been specially designed for this shafting. It should be specifically noted that only those parts and accessories supplied by Schottel GmbH have been tested and approved and therefore guarantee full functionality and safe operation. Please contact the SCHOTTEL Service Department if you have any queries.

2.6

Environmental protection

●

Any operating materials and other materials accumulated during installation are to be collected and disposed of according to national regulations applicable in the country of operation. Disposal is only allowed at the designated sites. Never allow environmental pollution to occur.

●

Operating materials must never be disposed of into the sewage system.

●

Special care is to be taken close to water. If operating materials get into the water this may cause irreparable damage to the environment.


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3

Introduction

3.1

Structure and mode of operation

Shafting systems transfer the rotational motion and power output of the engine/propulsion motor (e.g. combustion engine; AC motor) to the propulsion unit (e.g. SCHOTTEL rudder propeller). For manufacturing, installation and functional reasons, the shafting system cannot consist of one single piece. The following example demonstrates the structure of a shafting system (regardless of the different versions). Shafting systems come in different varieties depending on the type of vessel, the vessel's structure, or design factors. The versions presented in the following make up the most frequently used combinations of sub-assemblies; see figure 2. Due to the high number of possible variants, not all combinations can be presented. The size of shafts and bearings depends on the speeds and torques that are to be transmitted; (see 8 “Technical data“ section).

8

1

Fig. 1

2

3

4

5

6

9

10

11

7

Shafting structure (example)

1 Engine/propulsion motor 2 Flexible coupling 3 Countershaft 4 Cardan shaft 5 Intermediate shaft 6 Bulkhead seal


7 Flexible shaft 8 Belt pulley 9 Cardan shaft 10 Clutch 11 Rudder propeller 12 External flange bearing

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12

Fig. 2

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Shafting variants


4

Transportation and delivery

4.1

Transportation conditions DANGER

Suspended load Hazard to life or risk of serious injuries due to falling load ▶ Wear a safety helmet. ▶ Do not go or linger under suspended loads. Never leave components suspended in the slings over a long period of time. ▶ Only attach the sub-assemblies using the designated suspension points. ●

Transport safeguards must not be removed until installation.

●

Always transport parts horizontally. If upright transportation is unavoidable, shaft parts that move against each other, e.g. in cardan shafts, have to be secured to prevent them sliding out.

●

When moving by fork-lift truck, place wood underneath and only lift by the central part of the shafts.

●

Pay attention to the lubricating nipple. Suspension ropes must not be placed over the lubricating nipple.

●

Use synthetic ropes or lifting straps for crane transportation. If only steel ropes are available, use edge protectors on the attachment points.

4.2

Condition on delivery

The shafting sub-assemblies are supplied preserved and packed. Screws, bolts and lock washers for installing the shafting are part of the scope of delivery. Sub-assemblies not produced by SCHOTTEL GmbH may be supplied unassembled. These have to be assembled according to the corresponding manufacturer's documents for subsequent final assembly.

4.3

Inspection after delivery

The sub-assemblies are to be checked for completeness immediately after delivery. Get in contact with the SCHOTTEL Service Department straightaway if there any discrepancies with the delivery documents. Opened packaging is to be closed again after the inspection to protect the components from corrosion and damage. The supplied manufacturers' documents apply to sub-assemblies not produced by SCHOTTEL GmbH.


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5

Storage

5.1

Storage methods and storage periods

i

INFORMATION

The shafting sub-assemblies are preserved and packed prior to delivery. If stored in dry ambient air (not sea air), the preservative provides sufficient protection for approximately six months. The shafting is to be installed within these six months. If this is not possible, all necessary measures according to SCHOTTEL Instructions “Preservation Instructions” are to be undertaken. In the interim period between delivery and installation, or if work is interrupted, the shafting sub-assemblies are to be properly stored. After the inspection, the shafts and accessories are to be stored in the original packaging. The following instructions are to be observed in order to prevent damage caused by corrosion or incorrect storage. If necessary, consult the SCHOTTEL Service Department. ●

Store the shafting and accessories in a clean and dry place (e.g. warehouse). If this is not possible, the parts are to be covered with suitable means (e.g. tarpaulins).

●

Make sure there are no vibrations in the vicinity of the stored material.

●

Transport safeguards must not be removed.

●

Always store shafts horizontally.

●

Store the shafts and accessories on a suitable base, e.g. wooden pallet.

●

Only ever support shafts beneath the central shaft section. Joints, flanges, sliding elements, profile protection and lubricating nipples must not be covered or stressed.

●

Secure the shafts to stop them rolling away, if necessary, e.g. with wedges or prisms.

●

The cardan shaft joints must not be bent beyond the permissible value when in storage.

●

Do not stack shafts and their accessories. If items have to be stacked due to lack of space, wooden frames are to be used to stop the shafts being damaged or rolling away.


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6

Installation

6.1

Required working conditions

●

The instructions on the Installation Drawing and any individual drawings are to be observed.

●

The supplied manufacturers' documents apply to any sub-assemblies not produced by SCHOTTEL GmbH.

●

Make sure the ambient temperature specified in the Installation Drawing for the operating areas is upheld.

●

Casting resins may be harmful to health. Make sure the operating area is well ventilated during installation of the intermediate shafts.

6.2 ●

Operating materials

Fill the bearings in accordance with SCHOTTEL instructions “Installation Instructions for Self-Aligning Roller Bearings”.


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6.3

Documentation of measures; record sheets

Any alignment and checking work is to be documented. The necessary record sheets for this are provided by SCHOTTEL GmbH with the delivery or are to be drawn up by the shipyard. These records sheets are to be given to the employee authorised by SCHOTTEL GmbH for the start-up. Refer to the Installation Drawing, individual drawings and manufacturers' documents for values and tolerances. A hard copy is required of any record sheets drawn up. There are no special requirements for their design. However, SCHOTTEL GmbH states that record sheets should at least contain the following content: General information in all record sheets: ●

Customer and order number

●

Project identifier

●

Project name and identifier

●

Place and date of creation and last amendment

●

Person(s) responsible

●

Date and persons responsible for review and approval

●

Inspection/test item

●

Inspection/testing equipment

●

Inspection/test results with provision of units of measurement before and after installation.

Alignment record sheet for the cardan shafts: ●

Deflection angles ß1 to ß4 compliant with the supplied Alignment Data Sheet.

Alignment record sheets for intermediate shafts, bearings, couplings and other components: ●

Radial offset to opposite flange surfaces

●

Angular offset to opposite flange surfaces

In addition, all activities involved in aligning the shafting and its sub-assemblies are to be digitally photographed for the records and sent to SCHOTTEL GmbH prior to start-up. The photographs are to meet the following minimum requirements: ●

Components being photographed need to be easily identifiable; make sure there is sufficient illumination.

●

Make sure the photographs are always in focus and any markings clearly identifiable.

●

The photographs must fully document the installation and alignment procedures.

●

The working area is also to be included in the photographs to provide an overall impression of the propulsion system and work carried out.

●

Make sure the photographs depict the actual installation situation. Photographs of components or alignment work outside of the propulsion system is not permitted.

The minimum requirement is shots of the following: ●

General view of the shafting

●

Detailed shots of the bases and bearings during installation and alignment

●

Top view of the open floating bearings following alignment

●

General and detailed shots of screw connections

●

Shots of alignment of the cardan shafts with pointers (general and detailed shots)

●

General and detailed shots of the other sub-assemblies being aligned

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6.4

Alignment proposal for universal shafts

On principle power take off flange of clutch or shaft line have to be aliqned to the input flange of Rudderpropeller after installation of the Ruderpropeller in the ship.

6.4.1

Vertical alignment

1. Install clutch and/or shaft line and align them provisionally according to the dimensions shown on the approved SCHOTTEL installation proposal. 2. Put parallel rules vertically on the face of both the power take off flange of clutch and input flange of Rudderpropeller; length of parallel rules approx. 1500 mm. 3. Measure the distance between the flanges (rules) in a height of 1/2 h. The distance shall correspond with the distance stated in the SCHOTTEL installation proposal drawing. 4. Measure same distance on a radius of 1000 mm and align clutch and/or shaft line by putting distance pieces underneath the bearings and/or clutch until the figures are within a tolerance of ± 2 mm. 5. Fix clutch and/or shaft line provisionally and check again and correct if necessary.


23/40

6.4.2

Horizontal alignment

1. Put two parallel rules of exactly same breath vertically on the face of power take off flange of clutch and/or shaft line and fix it to the flange by clamps. Lenqthof rules at least h + flange diameter. 2. Put on rule horizontally across the vertical rules in a height of 1/2 h. Put a second rule horizontally on the face of input shaft of SRP in a height of 1/2 h also. 3. Measure the distance between the outer edges of the horizontal rules and addition the breath one vertical rule. The distance shall correspond with the figure stated in the approved SCHOTTEL installation proposal. 4. See „Vertical alignment“, step 4. 5. Fix clutch and/or shaft line on counter foundation and check alignment again and corret if necessary. 6. Check vertical alignment again and correct if necessary. 7. Fix and secure clutch undlor shaft line on the counter foundation and install universal shaft according to the separate instructions "Installation and maintenance of universal shafts".

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6.5

Types of bearing bases

The types of bearing bases (3/1) used is the shipyard's responsibility. SCHOTTEL GmbH requirements of the bearing bases are listed in the following: ●

Minimum rigidity 500 kN/mm

●

Capacity to support bearing mounts complying with 8.1 “Dimensions” section.

6.6

1

1

Installation of the intermediate shaft

The intermediate shaft is supplied with premounted bearings. The fixed bearing is marked on the bearing housing. Installation is to be carried out in accordance with the Installation Drawing and the drawing of the intermediate shaft.

1

Please note the following information: ●

The intermediate shaft is to remain movable until the cardan shaft is aligned with the pointers.

●

If there are any bulkhead seals, these are only to be bolted on once the intermediate shaft has been fully mounted and aligned.

●

Floating bearings may slip during installation or alignment; the self-aligning roller bearings (4/1) then lie against the bearing housing (4/2).

Fig. 3

Floating bearings have to sit in the centre of the housing to compensate any displacement during operation (e.g. also applies to deformation of the vessel's hull). ●

Make sure grease outlets are on the top side of the bearings.

●

Installation is to be documented by photographs; see 6.3 “Documentation of measures; record sheets”.

Bearing bases

1

2

Fig. 4


Checking the floating bearings are centred

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6.7

Alignment of the intermediate shaft and bearing

Testing and adjustment equipment: ●

Laser-assisted shaft alignment system (preferable)

●

Ruler

●

Own testing equipment suitable for measuring work.

Alignment of the intermediate shaft and bearings is to be recorded and documented in photographs; see 6.3 “Documentation of measures; record sheets”. Refer to the Installation Drawing and drawing of the intermediate shaft for measurements, limit values and tolerances. Measurements set out in the 8.1 “Dimensions” section also apply to the bearings. The bearings can be aligned sing spacers or casting resin. The following information applies when aligning the bearings using spacers: ●

Spacers must cover the entire flange surface.

●

The minimum thickness is 10 mm.

The following information applies when aligning the bearings using casting resin: ●

Only casting resin approved by the ship classification society is to be used.

●

The casting resin is to be cast by a specialist company.

●

Observe the specifications of the casting resin manufacturer regarding processing and curing times.

●

Align the bearing and fix into place using adjusting screws prior to casting.

●

In addition, an adequately sized plate is to be attached under the bearing foot.

●

Only tighten the bearing fastening screws/bolts once the casting resin has completely hardened.

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After alignment: ●

Check the floating bearings (5/1) are centred; align if necessary.

●

Use roll pins to fix the bearings into place.

●

Pin bearing mounts to the base.

i

1

INFORMATION

The pinning of the bearing mount and base is important for subsequent positioning during removal or maintenance and repair work. Refer to the bearing drawing for the number and position of the pin boreholes needed; see the 8.1 “Dimensions” section. ●

Screw on the bulkhead seal, if present; see 6.10 “Installation of the bulkhead seal” section.

Fig. 5


Checking the floating bearings are centred

27/40

6.8

Alignment of the cardan shaft deflection angles using pointers

The deflection angle is aligned prior to installation. Pointers are mounted instead of cardan shafts. ●

Cardan shafts may have different lengths and deflection angles.

●

However, the deflection angles of a cardan shaft have to be identical.

●

Refer to the Installation Drawing for permissible lengths and deflection angles.

●

Every cardan shaft is to be aligned separately.

●

Both pointer tips of a cardan shaft must be the same length. The lengths are to be checked prior to alignment and adjusted if necessary.

●

Alignment of the deflection angle is to be recorded and documented in photographs; see 6.3 “Documentation of measures; record sheets”.

Fig. 6

28/40

Alignment of the cardan shafts


NOTICE Damage to the shafting due to incorrect installation and alignment Incorrectly installed and aligned cardan shafts produce forces and vibration which may destroy the shafting and attachment parts, as well as the engine/ propulsion motor or gears. ▶ The cardan shafts are to be aligned prior to installation. ▶ Always observe the permissible tolerances.

i

INFORMATION

The shipyard is responsible for providing the pointers. SCHOTTEL will provide a drawing to use for their production. Please contact the SCHOTTEL Service Department if you have any queries. 1. Mount four pointers on the counter flanges of the cardan shafts. 2. Shift the shafts until the tips of the pointers touch. 3. Measure any deviations at the pointer tips. The maximum permissible deviation at the pointer tips is 2 mm in any plane. 4. Shift the shafts until the deviation at the pointer tips is within the permissible tolerance. If necessary, adjust the length of the pointers. However, both pointers on a cardan shaft must be the same length. 5. Enter the measured values on the alignment record sheet.


29/40

6.9

Installation of the cardan shaft

The cardan shaft deflection angles are to be aligned using pointers prior to installation; see 6.9 “Alignment of the deflection angle of the cardan shafts using pointers” section.

INFORMATION

i

If the angle is off, bolts cannot always be inserted from the cardan shaft side. To make installation easier the bolts are to be inserted from the intermediate shaft flange side and the nuts screwed on from the opposite side. This also makes it easier to check bolted connections during start-up, as loose nuts are immediately noticeable. ●

Remove any transport safeguards prior to installation.

●

Clean any dirt, grease, anti-rust agents and paint from the front sides of the cardan shaft flange and connecting flange prior to installation.

●

Check the connecting flange prior to installation. Its shape and size must conform to the respective cardan shaft flange.

●

Never swap the sliding element or other cardan shaft parts of different cardan shafts. The cardan shafts would otherwise be incorrectly balanced.

●

If it is necessary to pull the the cardan shaft completely out of the sliding element the exact marking is to be observed when putting both components back together.

●

Never turn the cardan shaft by the joint with assembly tools, such as push-on pipes or lever rods. Lubricating nipples and seals may become damaged.

●

For shafting with two cardan shafts these have to be installed offset at 90° to each other.

●

If the cardan shaft is painted, make sure that the area for length compensation is not painted.

●

Check whether the cardan shaft is assembled exactly according to the marking on the sliding element.

30/40

NOTICE Damage to the cardan shaft due to incorrect installation If the cardan shaft length compensation section is mounted right up to the limit stop, damage may occur to both the cardan shaft and the entire shafting due to thermal expansion during operation. ▶ Therefore, align the cardan shaft so that there is enough room for length compensation on both sides following installation. ●

Align the cardan shafts with the connecting flanges and mount.

●

Observe the required torque; see the Installation Drawing in the supplied documents.


6.10

Installation of the bulkhead seal

The bulkhead seal is to be installed according to the Installation Drawing and the drawing of the intermediate shaft. ●

Bulkhead seals are only to be bolted on following alignment of the intermediate shaft.

●

Transport brackets are to be removed prior to fixture.

Bulkhead seals may be versions with radial or axial seals. The following information is to be observed for installation: ●

For intermediate shafts that need smoothing in the bulkhead seal area make sure the smoothed areas are absolutely clean.

●

The bulkhead seal is only to be shifted within the shaft's smoothed area.

6.11

Installation of other shafting sub-assemblies

Other sub-assemblies (e.g. belt pulleys and clutches) are to be installed according to the Installation Drawing and individual drawings. Any sub-assemblies not produced by SCHOTTEL GmbH (e.g. flexible couplings and shafts) are to be installed according to the Installation Drawing and manufacturers' documents.

NOTICE Risk of damaging the cardan shaft due to incorrect installation Check the specified direction of rotation when installing components. ▶ Refer to the supplied drawings or manufacturers' documents.


31/40

6.12

Checking the shafting

Testing and adjustment equipment: ●

Laser-assisted shaft alignment system (preferable)

●

Ruler

●

Own suitable inspection/testing equipment for the inspection/testing

Once the shafting is installed and aligned the following aspects are to be fully checked: ●

Adherence to measurements and tolerances.

●

Adherence to the required torques for screw connections.

●

Correct installation and filling of the bearings with permitted operating materials in compliance with the SCHOTTEL "Installation Instructions for Self-Aligning Roller Bearings".

●

Pinning of the bearing mounts to the bases.

●

Obvious damage to shafting components.

●

Proper performance of installation and alignment work.

i

INFORMATION

Refer to the Installation Drawing, individual drawings, manufacturer's documents and supplied documentation for the measurements, tolerances and adjustment values.

32/40


7

Start-up

Start-up is carried out by an authorised SCHOTTEL GmbH employee and documented in a commissioning report. After start-up, the whole system supplied by SCHOTTEL is transferred to the responsible division of the shipyard until its handover to the operator. The system has to be prepared for the start-up. In this respect, the measures set out in the "6.12 “Checking the shafting“ section have to be completed and those described in the following carried out: ●

Compilation of the necessary record sheets to hand over to the authorised SCHOTTEL GmbH employee.

●

Ensuring that the necessary safety measures for start-up are in place as set out in the 2.2.5 “Safety instructions for start-up“ section”.

●

Making all necessary preparations for start-up in accordance with the operating instructions for the sub-assemblies of the entire system; e.g. propulsion unit, hydraulic system, control and electrical systems.

During start-up, adherence to limit values for vibration and temperatures are checked, as are any unusual noises from the shafting.

i

INFORMATION

Bearing temperatures may be increased (up to 130 °C) during the shafting run-in period. Once the seals have been run in and grease has been evenly distributed in the bearings, the temperatures will drop to a normal level (< 80 °C). Fig. 7


Vibration velocity (RMS) in the bearing housing

33/40

8

Technical data

8.1

Dimensions

Refer to the Installation Drawing and individual drawings for the dimensions of the different shafting sub-assemblies and their respective weights. The following table and drawings apply to the installation and alignment of the bearing mounts and bearings. Measurement table for the various types of bearing installation Ref.

Unit

Shaft diameter

a

mm 180

170 150 140 125 110 100 90

80

Housing centre

b

mm 190

180

170

170

150

140

125

112

100

Housing base

c

mm 80

75

70

60

50

45

45

40

35

Spacer length

d

mm 590

590

590

600

550

460

460

420

420

Spacer width

e

mm 240

240

240

235

205

185

175

160

160

Bearing plate length

f

mm 760

760

760

760

620

580

580

570

570

Bearing plate width

g

mm 380

380

380

380

350

290

230

180

180

Borehole spacing for h fastening screws/ bolts

mm 480

450

430

470

420

350

350

320

290

Borehole spacing for i fastening screws/ bolts

mm 120

110

100

-

-

-

-

-

-

Borehole spacing for j adjusting screws

mm 680

680

680

670

620

580

530

520

520

Borehole spacing for k adjusting screws

mm 200

200

200

170

170

170

180

130

130

Borehole spacing for l fastening screws/ bolts

mm 600

570

570

590

540

450

490

460

460

Borehole spacing for m fastening screws/ bolts

mm 300

260

260

250

250

220

-

-

-

Bearing plate thick ness

n

mm min. 40

min. 40

min. 40

min. 40

min. 40

min. 40

min. 40

min. 40

min. 40

Casting resin layer

o

mm 20

20

20

20

20

20

20

20

20

Cast riser

p

mm 15

15

15

15

15

15

15

15

15

Joint

q

mm 20

20

20

20

20

20

20

20

20

Spacer thickness

r

mm 12

12

12

12

12

12

12

12

12

Roll pin Ø

s

mm 20

20

20

12

12

8

8

8

8

Roll pin position

t

mm 520

490

470

506

458

378

378

348

317


35/40

Measurement table for the various types of bearing installation Roll pin position

u

mm -

-

-

58

54

44

44

39

35

Tightening torque

v

Nm

350

350

350

350

350

200

200

200

150

Housing fixture

w

Nm

665 (M24)

665 665 1310 1310 665 665 665 386 (M24) (M24) (M30) (M30) (M24) (M24) (M24) (M20)

Casting resin fixture to base

x

Nm

1350 (M30)

1350 1350 1350 1350 670 670 670 670 (M30) (M30) (M30) (M30) (M24) (M24) (M24) (M24)

36/40


1

b

2

r

s

3 4

a

t

d h

6

i e

Fig. 8

ÇÇ Ó Ó ÇÇ Ó Ó ÇÇ ÓÓ Ó c

ÇÇ ÓÓ Ó ÇÇ Ó ÇÇ

5

Bearing installation using spacers (for shaft diameters > 100 mm)

1 Base 2 Limit stops and adjusting bolts (installed by the yard) 3 Roll pin „s“ (installed by the yard) 4 Fastening screws „x“ (installed by SCHOTTEL) 5 Fastening screws „y“ (installed by the yard) 6 Spacer „r“ (installed by the yard)


37/40

1

2

o

k m g

Fig. 9

l

f

j

q

3

p

ÓÓ Ç ÓÓÇ Ó ÓÓÇ Ó ÇÇ Ç ÓÓÇ ÓÇ ÓÓ Ó Ç Ô ÓÓ Ó Ç ÓÓ Ó Ç ÇÇ Ç ÓÓ Ó Ç ÓÓ Ó Ç ÓÓ Ç ÓÓ

4 5

a

6 7 8

n 9

Bearing installation using casting resin (for shaft diameters > 100 mm)

1 Base 2 Limit stops and adjusting bolts (installed by the yard) 3 Casting mould 4 Adjusting screws (installed by the yard, to be removed after casting process) 5 Roll pin „s“ (installed by the yard) 6 Fastening screws „x“ (installed by SCHOTTEL) 7 Fastening screws „y“ (installed by the yard) 8 Fastening screws „z“ (installed by the yard) 9 Mounting plate „n“

38/40


1

c

2

b

s

3 4

t

h

d

r 6

a

5 u e

Fig. 10

Bearing installation using spacers (for shaft diameters < 110 mm)

1 Base 2 Limit stops and adjusting bolts (installed by the yard) 3 Roll pin „s“ (installed by the yard) 4 Fastening screws „x“ (installed by SCHOTTEL) 5 Fastening screws „y“ (installed by the yard) 6 Spacer „r“ (installed by the yard)


39/40

1

p o 2 4

3

l

j

f

q

5

Ö Ö

6 a 7 8 n

9

k g

Fig. 11

Bearing installation using casting resin (for shaft diameters < 110 mm)

1 Base 2 Limit stops and adjusting bolts (installed by the yard) 3 Casting mould 4 Adjusting screws (installed by the yard, to be removed after casting process) 5 Roll pin „s“ (installed by the yard) 6 Fastening screws „x“ (installed by SCHOTTEL) 7 Fastening screws „y“ (installed by the yard) 8 Fastening screws „z“ (installed by the yard) 9 Mounting plate „n“

40/40


16

15

14

13

12

11

10

9

F 1:1

M

44

43

40

37

41

42

8

7

39 30

1

6

5

4

3

201 86

10°

32(2x) 17

5

57

L

45° 125

15

A

D

Flansch (Flange): 8x45°- Ø14,1 8x45°- M14

K

D-D

8x M14

25,36

35

23,35

280

E

50 (1x)

K

A

ca.20 466,72

12

110 h6

38

0 .4 ca

180

46

0 .4 ca

15

7

M

E-E

F

r.

K 3 1:1

°

c.

K

47,48,49

10

b.

1

45

252,5

L

50 (2x)

17

2

38

8

E

80

3

3

26,36

J

J

35

145

35

D

0° 36 (=

8x

155,5 ±0,10

45 °

63,7

°

12,5

)

8x 14,1 45

a.

H

8x

10

45

°(=

H

36

45° 0°)

4 158,5

25

G

4

5

6

Achtung! Keilriemen lose aufgelegt, nach Montage der Schaltkupplung an Motor gem.1170951 nachspannen. Attention: V-belt lead on loose after mounting of the clutch to the engine the v-belt must be tightend after installation instruction 1170951.

J F

E

10

G

Bei Verwendung von Schrauben der Güteklasse 10.9 sind Scheiben mit den Abmessungen Ø26x4 unterzulegen. With bolts of quality 10.9 washers with diameter Ø26x4 have to be used.

B

A-A

Einbau-und Betriebsanweisung Kupplungskombination, zusätzlich auch Einbau und Betriebsanweisungen des Elastikkupplungshersteller.

Installation and operatin instruction clutchkombination, see the installation and opreration instruction of the elastic coupling producer.

27

MA=20Nm

F

Achtung!

Keilriemenschutz bei Montage angepasst! Belt drive protection aduated when mountig!

Das konstrukiv festgelegte Kurbelwellenaxialspiel des Motors darf durch dass Anflanschen von Kupplungen oder Anbauteilen auf keinen Fall vermindert werden! Es ist deshalb unerlässlich, vor und nach dem Anflanschen von Anbauteilen das Kurbelwellenaxialspiel zu erfassen. Sollten die Ergebnisse beider Messungen nicht überseinstimmen oder federt die Kurbelwelle nach dem verschieben zurück, ist der Anbau zu überprüfen.

40

35 31

H

J

e

Screw quality 10.9 tightening torque to be abserved!

B 22 1:1

5

dw= 200

H 1:1

Schraubenqualität 10.9 Anzugsmomente bechten!

Transport hold: before mounted at the engine to remove 2x item 22 a. 31, to change with screws from the customer.

8 3xSPB, Lw=1550

2

To fasten with "Loctite 245" ID-Nr: 1048197

420

Transporthalterung: 2xPos.22 u. 31 vor Anbau an Motor entfernen und durch kundenseitige Schraubenverbindung ersetzen.

592

45

Gesichert mit "Loctite 245" ID-Nr: 1048197

22,5°

C 1:1

C

33

24

E

Attention!

35

The crankshaft axial play of the engine determined at the design stage must under no circumstances be reduced when couplings or other add-on components are flanged on. It is therefore of paramount importance that the crankshaft axial play before and after add- on components are flanged on. If the readings of the two measurements deviate from each other, or the crankshaft spring back after having been shifted, the add-on components must be checked again.

44

D

13

20 1

10

16

Überall dort, wo eine Gefährung von Menschen und Material durch rotierende Teile möglich ist, sind vom Anwender und/oder Betreiber entsprechende Sicherheitsvorkehrungen zu treffen.

Keilriemenscheibe zur Montage auf 80°C erwärmen. Nicht schlagen oder pressen! V-belt pully heated up to 80°C mounting. Don't push or press!

11

114 64

°

190

32

Abnahmepruefzeugnis DIN EN 10204: 2005-01- 3.2 nach den gueltigen Vorchriften der mitgeieferten Schiffsklassifikationsgesellschaft.

F N O C

6

MA=250Nm

G

21 2

4 2

3 37,5

°

3.2 3.1 3.2

1121308 1122076 1122076

2611 2611S 2611S

1208981 1206685 1204199

Pos.2 Abnahme Approval

Pos.2 Teilenummer Partnumber

Pos.2 Baugrösse Size

Teile-Nr. K200 Part-No. K200

Dieser Entwurf ist geistiges Eigentum Schutzvermerk DIN ISO 16016 beachten der SCHOTTEL GmbH Werkstueckkanten DIN ISO 13715

28,34

-0.3

Projektionsmethode 1 DIN ISO 128 +0.8

A

15

14

9

12

004 15/0310 003 002 001

14/2776 14/2637 14/1587

000

0000

02.02.2015

NoetzelK 02.10.2014 NoetzelK 22.09.2014 NoetzelK 05.06.2014 NoetzelK 19.05.2014 NoetzelK

Zust. Aenderung Datum

16

15

14

13

12

11

10

9

8

L

A I T N IDE

150

37

29

B

C

Inspection certificate DIN EN 10204: 2005-01-3.2 acc. to the rules of the demanded ship classification society.

280

33,5

Konservierung gemäss Auftrag. Conservation lack at the order

4

438,2 - 8x45°

G 1:1 C

Vorhandene Schrauben verwenden! Existing screw to use!

J-J

Where danger to the people or material can be caused by rotating parts, a saftey device has to be installed by the user and/or operator.

35(2x) 23

37,5

D

7

6

5

4

3

Name

Allgemeintoleranz DIN ISO 2768-mK Schweisskonstr. DIN EN ISO 13920-C Tolerierung DIN ISO 8015 Oberflaechenangaben DIN EN ISO 1302

Name Datum Bearb. 19.05.2014 NoetzelK Gepr. 15.01.2014 PickM AV 16.01.2014 LangF Norm 09.02.2015 MalewskiD Abt. SCHOTTEL GmbH Mainzer Strasse 99 D-56322 Spay/Rhein Urspr.:

Bemerkung Remark

CAD-ZEICHNUNG Manuelle Aenderung verboten ! Massstab: 1:2.5 Werkstoff: Rohteil-Nr.: Modell-Nr.:

Typ: K 200 Gewicht: 386.00 kg

Benennung:

Schaltkuppl. vollst.HY-Pumpe SAE 1/14Z Vulkan D180 Version2 Clutch cpl. HY-pump

Zeichnungs-Nr.

1204199 Ers. f.:

2

B

Index: 004

Format

Bl.Nr.: 1 von 1 Ers. d.:

1

0

A

Operating instructions 

Planox Clutch Model: PHRTA 143/1

Manual: BAL DE-0597347-0 Translation of the original operating instructions Keep all information delivered with the product for later use and pass it on to the new buyer when selling the product.

Operating Manual

BAL EN-0597347



Planox -Clutch type PHRTA 143 Drawing: 0597347 -0/33 297062

Contents 1

Product overview .................................................................................... 4

1.1

List of parts.................................................................................................................. 4

1.2

Spare parts / wear parts .............................................................................................. 6

1.3

Drawing ....................................................................................................................... 7

1.4

Technical data ............................................................................................................. 8

2

Notes ...................................................................................................... 9

2.1

Basic safety instructions .............................................................................................. 9

2.2

Safety and information signs ..................................................................................... 11

2.3

Notes concerning the operating manual.................................................................... 11

2.4

Notes concerning suppliers’ documentation.............................................................. 12

2.5

Service ...................................................................................................................... 12

3

Transportation and storage................................................................... 13

3.1

Scope of delivery....................................................................................................... 13

3.2

Transportation ........................................................................................................... 13

3.3

Storage...................................................................................................................... 13

4

Technical description ............................................................................ 14

4.1

Notes concerning the product ................................................................................... 14

4.2

Function specification................................................................................................ 14

4.3

Operating pressure ................................................................................................... 14

4.4

Installation space ...................................................................................................... 14

5

Installation / Assembly .......................................................................... 15

5.1

Fitting the clutch ........................................................................................................ 15

6

Commissioning ..................................................................................... 16

6.1

Measures that must be taken by the customer before putting the clutch into operation .... 16

6.2

Test run at no load .................................................................................................... 16

Issue: February 2014

Page 2

Operating Manual

BAL EN-0597347




7

Operation .............................................................................................. 17

7.1

Operating behaviour .................................................................................................. 17

7.2

Safe use .................................................................................................................... 17

8

Maintenance and repair ........................................................................ 18

8.1

Maintenance interval ................................................................................................. 18

8.2

Checking for wear ..................................................................................................... 18

8.3

Overview of wear parts.............................................................................................. 18

8.4

Checking related parts for wear ................................................................................ 19

8.5

Servicing the friction discs. ........................................................................................ 19

8.6

Servicing the roller bearings. ..................................................................................... 19

8.7

Servicing the seals .................................................................................................... 19

8.8

Maintaining the control switch (130) .......................................................................... 20

8.9

Repairing the Planox clutch ..................................................................................... 20

9

Faults and remedy ................................................................................ 21

9.1

The clutch slips under load ....................................................................................... 21

9.2

Hub and pressure disc heat up over 120 °C while switched on ................................ 21

9.3

Hub and pressure disc heat up while switched-off .................................................... 21

10

Ordering spare parts ............................................................................. 21

11

Checking for radial and axial run-out .................................................... 22


Page 3

Operating Manual

BAL EN-0597347




1

Product overview

1.1

List of parts No.

Qty.

1

1

Toothed ring

2, 12

1

Clutch hub with bolt

3

2

Inner disc

4

1

Pressure disc

14

12

Hex. screw ISO 4017 - M10x35 - 8.8

17

324

Belleville spring 40/20.4x1 L0=2.3

27

3

Friction disc

31

1

Bell

36

1

Shaft

42

2

Grooved ball bearing

43

1

Ring

44

12

Shim ISO 7092-8-200 HV

45

12

Socket head cap screw DIN 6912 - M10 x 1 - 8.8

46

12

Pressure spring

47

1

Grooved nut KM 12

48

1

Lock washer MB 12A

49

2

Cover plate

53

6

Piston guide sleeve

55

1


56

8

Hex. screw ISO 4017 - M6x16 - 8.8

58

8

Socket head cap screw ISO 4762 – M8x25 – 10.9

59

1

Grooved ring C2 - 220/200x14

60

1


61

1

Piston

62

1

Guide strip

63

1

Backing disc DIN 988 -S100x120x3.5

64

1

SI ring DIN 471 - 100x3

67

330 mm


Name

Felt strip

Page 4

Operating Manual

BAL EN-0597347




No.

Qty.

68

1

End plate

71

1

Fitting key DIN 6885-A20x12x100

73

6

Socket head cap screw ISO 4017-M10x60-8.8

74

1

Pressure ring

75

6

Guide bolt

80

1

Ring

81

2


82

1

Sleeve

83

2

SI ring DIN 472 - 120x4

85

1

Backing disc DIN 988 -S60x75x3

91

1

Ring

93

1

Intermediate housing

95

1

Flange

96

1

Disc

97

1

Key DIN 6885 - B18x11x75

98

1

Hex. screw ISO 4017 - M20x50 - 8.8

100

1

Eye bolt DIN 580 - M20 - C15

125

1

intermediate flange

126

1


127

1

Pressure ring

128

1

Hex. screw ISO 4017 - M12x35 - 8.8

129

1

O-ring 24x3

130

1

Control block

131

4

Socket head cap screw ISO 4762 – M8x60 – 8.8


Name

Page 5

Operating Manual

BAL EN-0597347




1.2

Spare parts / wear parts Wear parts Pos 1

Qty.

Name

1

Toothed ring

2, 12

1

Clutch hub with bolts

3

2

Inner disc

4

1

Pressure disc

17

324

27

3

Friction disc

46

12

Pressure spring

Belleville spring 40/20.4x1 L0=2.3

Roller bearing Pos

Qty.

Name

42

2


81

2


126

1


Seals Pos

Qty.

59

1


60

1


62

1

Guide strip

67

330 mm

129

1


Name

Felt strip O-ring 24x3

Page 6

Operating Manual

BAL EN-0597347



Planox -Clutch type PHRTA 143 Drawing: 0597347 -0/33 297062 1.3

Drawing


Page 7

Operating Manual

BAL EN-0597347




Technical data

1.4.1

Planox clutch

®

The technical data and dimensions of the clutch may be found in the drawing enclosed with the design concerned. Torque Switching torque Operating speed Switching speed Operating pressure Required venting pressure Oil requirement Oil grade Ambient temperature Operating temperature Installation dimensions: Length Diameter Weight 1.4.2

Tü max. = TS n max. = ns approx. pmax = pmin. = VSwitch approx. max. max. max. max. approx.

4300 3600 2350 650 ±3 45 35±2 0.33 HLP 32 40 80

Nm Nm rpm rpm bar bar litres °C °C

595 mm 552 mm 253 Kg

Vibration clause: Vibration and excitation are generated in machines, and these may affect our product. As, however, the dynamic design of the entire drive line, of which our product is part, is the responsibility of the manufacturer of the machine, we recommend that you perform a machine-dynamic inspection on the drive line and, if necessary, carry out vibration calculations and/or measurements. On request, we can assist you in this on agreeing a separate contract. As a merely precautionary measure, we would like to point out that we assume no responsibility for damage of any kind caused by vibrations and excitations unless the dynamic requirements of the product have been specified by the customer. With regard to this, we refer you to section VI, 5 and sections VI and VII of our general terms of business.

1.4.3

Identification of the clutch The identification is on: –

rating plate on the bell (31)

–

toothed ring (1) – face side


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2

Notes

2.1

Basic safety instructions •

The operator is responsible for ensuring that the persons assigned the tasks of fitting, operating, servicing and repairing have read and understood the operating manual and observe its instructions in all points in order to: – prevent danger to life and limb of the user or a third party, – ensure the operational safety of the drive unit – ensure there are no losses of use or harm to the environment caused by false handling

2.1.1

•

The relevant work safety and environmental protection regulations should be observed during transportation, assembly, dismantling, operation, maintenance and repair work.

•

The Planox® clutch may only be operated, serviced and repaired by authorized, trained personnel who have been instructed on its use.

•

Work on the Planox clutch may only be carried out with the drive motor at a standstill. Secure the drive motor against accidental switching on, for example, by removing a fuse in the power supply or by putting up a sign indicating that work is being carried out on the clutch.

®

Safety instructions relating to incorporating the clutch into other products •

When incorporating the clutch into devices or systems, the manufacturer of these products is obliged to – check that the use of the Planox® clutch is permitted in these products and – to incorporate the prescriptions, instructions and descriptions contained in this operating manual into the operating manual of the product in question.

2.1.2

•

Changes on the Planox clutch may only be carried out with the manufacturer’s express permission.

•

The permissible load specifications (see chapter 1.4 “Technical Data”) may only be exceeded with the written consent of DESCH.

®

Safety instructions relating to operation •

Rotating parts must be protected against contact by appropriate safeguards. The performance of the clutch must not be impaired by the safeguards.

•

The drive unit shall be shut down immediately if noises and vibration different from those of normal operation are detected in the clutch during operation.

•

The permissible load values and the maximum speed as specified in the drawing or catalogue may not be exceeded.

• The control switch (130) contains hydraulic components to which special safety

requirements apply. In this connection, you must observe the manufacturer information.


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2.1.3

2.1.4

•

The specified switching pressure limits must not be gone below or exceeded. When the pressure is too low the clutch slips, while excessive operating pressure can ® destroy the Planox clutch. Even short-term pressure increases (to clear a blockage for example) are not permissible.

•

The heat arising during the engaging process is to be dissipated by means of sufficient aeration.

•

Switching noises arising during operation are to be absorbed by means of appropriate sound attenuation provisions.

Safety instructions relating to cleaning and upkeep •

It is very important that the friction pads be kept free from grease and oil, since otherwise insufficient coupling torque can be transmitted.

•

The friction pads may not be cleaned with solvents such as gasoline, acetone or petroleum. They must be replaced with new ones if they have become covered in oil or soiled.

•

Greasing or corrosive cleaning agents may not come in contact with the clutch.

Safety instructions relating to fitting, servicing and maintenance •

Careful, there is a danger of injuring by burning when performing repair and ® servicing tasks on the Planox clutch at operating temperature.

•

The permissible alignment values may not be exceeded.

•

The impermeability of the pressure oil supply line and the switching unit should be checked.

•

When mounting the accessories for the pressure oil supply, the safety and operation provisions applying here should be observed.

•

Improper dismounting of the Planox® clutch can lead to injury. Note that the clutch is under spring tension.

•

Screws coming loose can cause failure of the Planox® clutch. It is very important that the prescribed tightening torques be kept to.

•

All assembly aids must be removed and all safeguards put in place before commissioning.

Our assembly specialists are at your disposal on request for repair and servicing tasks. In this way, faults resulting from tasks incorrectly carried out can be avoided.


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Safety and information signs DANGER

Possible risk of serious or fatal personal injury.

W A R N I N G Possible risk of serious personal injury.

C A U T I O N Possible risk of personal injury and damage to the machine / clutch.

N O T E Indicates important information. 2.3

Notes concerning the operating manual This operating manual is an integral part of the delivery package and should be stored permanently in the vicinity of the drive unit. DANGER The safety instructions of this operating manual as well as those of the suppliers’ operating manuals must be observed. We accept no responsibility for damage and malfunctions resulting from the failure to observe the instructions in the operating manuals. The clutch described here is state of the art at the time of printing of this operating manual.

2.3.1

Diagrams All illustrations in this operating manual are diagrammatic only. Deviations from the representation are possible depending on model and size.

2.3.2

Copyright declaration All drawings are subject to copyright protection. The distribution or reproduction of these documents or the exploitation or communication of their content is not allowed unless permission has been expressly granted. Violations oblige for compensation. All rights are reserved in the case of the grant of a patent or the registration of an industrial design.


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Planox -Clutch type PHRTA 143 Drawing: 0597347 -0/33 297062 2.3.3

Intended use The clutch is designed only for the range of application of the technical data given in the chapter “Technical data” or on the drawing. Operating conditions other than these require new contractual agreements. The clutch acts as a connecting element between the drive and the driven machine in the commercial sector. Proper use includes:

2.4

–

use within the scope of the “Technical data”,

–

the observance of the instructions in the operating manual,

–

the appreciation that modifications, changes and adding accessories are only permitted with the written consent of the manufacturer.

Notes concerning suppliers’ documentation In addition to this operating manual, you must observe the information in the suppliers’ documentation; this applies in particular to the control switch (130). In particular, this includes the safety information as well as the information on maintenance intervals.

2.5

Service Our assembly specialists are at your disposal on request for repair and servicing tasks. In this way, faults resulting from tasks incorrectly carried out can be avoided.

2.5.1 Manufacturer's address Europe

Canada/USA

DESCH Antriebstechnik GmbH & Co. KG Kleinbahnstr. 21 D-59759 Arnsberg

DESCH Canada Ltd. 240 Shearson Crescent N 1T 1J6 Cambridge, Ontario Canada

Phone:

+49 2932 300 - 200 (Service)

Tel. Free.: Phone:

800 2 63 18 66 001 519 6 21 45 60

Fax:

+49 2932 300 - 154 (Service)

Fax:

001 519 6 23 11 69

E-mail:

[email protected]

E-mail:

[email protected]

Internet:

www.desch.de

Internet:

www.desch.on.ca


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3

Transportation and storage

3.1

Scope of delivery The contents of the delivery package are listed in the transport documents. Verify completeness of the delivery on reception. Any transport damage and/or missing parts must be reported immediately in writing.

3.2

Transportation Danger! Appropriate means of transportation that are equipped to bear the weight of the clutch are to be used for the transportation of the Planox® clutch. The Planox® clutch must be transported in such a way that the complete drive is not exposed to excessive impact loads, is protected against moisture and cannot slip.

3.3

Storage ®

The Planox clutch clutch is supplied in a preserved condition and can be stored in a closed, dry place for up to 6 months. Appropriate long-term preservation measures are required for a longer storage period (consultation with DESCH required). Caution! Preserving agents, greases or oils must not come into contact with the friction surfaces! This leads to a malfunction of the DESCH clutch. •

After approx. 6 months, the preservation, particularly that of the mating faces, must be checked and, if necessary, cleaned and preservation reapplied.

•

Close or cover all openings.


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4

Technical description

4.1

Notes concerning the product The Planox® clutch, model PHRTA is supplied ready for installation and is tested before dispatch. All the parts listed in the parts list belong in the scope of supply. The more carefully and conscientiously installation, commissioning and servicing are carried out, the more reliably the drive functions and the longer the service life of the Planox® clutch.

4.2

Function specification With the hydraulically detachable Planox clutch type PHRTA the oil is radially fed into the cylinder chamber from outside. The switching section consists of cylinder (designed as a bell Pos. 31), piston (61), grooved ball bearing (55), pressure ring (74) and is sealed by groove rings (59+60). In depressurized state the contact forces applied by the Belleville spring columns transfer the torque introduced via coupling hub (2) and bolts (12) to the ring gear (1) via the gearing of the friction discs (27). By feeding oil radially through the cylinder/bell housing (31) into the cylinder chamber, the piston (61) applies pressure on grooved ball bearing (55) and pressure ring (74) and thus acts on the guide bolts (75) radially arranged around the circumference, which compresses the Belleville springs. This causes ventilation between pressure disc (4), inner disc (3), outer disc (27) and clutch hub (2). The torque is no longer transferred (the clutch is switched off). In switched off state the piston is returned to its initial position by the pressure spring (46). Caution! When engaging, the oil may only flow in throttled, e.g. through a throttle, in order to avoid damage caused by high inrushes in the clutch. A tooslow engaging sequence can cause the clutch to slip and destroy it. For this, there is a control block (130) upstream of the clutch whose function you must inspect and ensure on a regular basis.

4.3

Operating pressure The operating pressure is max. 45 bar. The required switch off pressure is min. 35 bar. It must be checked at specific intervals. The transferable torque depends on the contact force of the Belleville spring columns.

4.4

Installation space The installation space for the Planox must be dry. Furthermore, it must be ensured that the friction surfaces will stay free of oil and grease. The installation space is dimensioned so that a sufficient amount of cooling air is direc6ted to the Planox.


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5

Installation / Assembly WARNING Incorrect assembly can result in the failure of the safety function of the drive unit. The instructions regarding the required tightening torque for the screws in the drawing and documentation of the suppliers are to be observed. CAUTION Preserving agents, greases or oils must not come into contact with the ® friction surfaces! This leads to a malfunction of the Planox clutch. Observe the manufacturer’s instructions when handling solvents. The mating faces should be rubbed with a lint-free, lightly-oiled cloth in order to facilitate subsequent dismantling.

5.1

Fitting the clutch Preliminary tasks:

Installing the clutch:

•

Remove the preservative using petrol or cleaning benzene.

•

Mount the hydraulic pump including the V-belt profile SPB to the intermediate housing (93).

•

Check the mounting and installation dimensions against the drawing.

•

Mount the elastic coupling and the intermediate flange (125) to the wedge plate / ring gear (1) or the flywheel of the diesel engine.

•

Remove cover plate (49) from the bell housing (31).

•

Push the bell housing (31) with intermediate housing (93) and complete Planox clutch into the centring of the engine housing and fasten it with screws. Two stud bolts may be screwed into the engine housing as assembly aids to take the weight of the bell housing and to ease insertion ATTENTION Skewing can cause damage to the roller bearing (126).

Assembling the oil supply:


•

Connect the oil feed to the control switch (130). The required oil pressure can be taken from the “1.4 Technical Date” for the Planox clutch. It must be checked at specific intervals.

•

Apply pressure to the clutch at standstill

•

Perform a leak test.

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6

Commissioning

6.1

Measures that must be taken by the customer before putting the clutch into operation The following measures are to be taken by the customer in order to avoid residual risks: CAUTION - safeguard rotating parts against contact. - dissipate heat generated in the drive unit during operation by means of aeration. - dampen switching noises by applying appropriate sound protection measures. Experience has taught us that proceeding with the utmost care and cleanliness is of particular importance when putting new systems into operation. Leaks arising shortly after the putting into operation procedure can be traced back without exception to a contaminated flow medium. It is thus important when assembling new systems to flush all conduits and containers in the interest of all hydraulic parts, and only then to put the system into operation.

6.2

Test run at no load CAUTION Damage or increased wear caused by engaging under load. Impact forces can damage the clutch when engaging under load, and a slipping of the clutch when engaging can result in premature wear. Adjusting the hydraulics:

Test run:


•

The clutch is switched off by applying hydraulic oil. The specified operating pressure (see item “1.4 Technical Date”) must be strictly complied with and should be checked from time to time

•

Set the pressure relief valve to a max. operating pressure of 45 bar and the pressure switch to the minimum operating pressure of 35 bar.

•

Start the engine.

•

Engage drive unit.

•

Allow the drive unit to run for a relatively long period until the operating temperature of the clutch remains constant.

•

Check the oil pressure display.

•

Check connections for leaks.

•

Engage the clutch several times.

•

Check the operating temperature. (approx. 50 - 80 °C)

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7

Operation

7.1

Operating behaviour Be alert for the following irregularities when operating the drive unit: –

unusual running noises

–

vibrations that occur

–

sudden jolts If these irregularities arise, switch the drive unit off immediately and determine the cause by referring to the troubleshooting chart (chapter “9. Faults and remedy”). If the cause cannot be determined or there is no possibility of repairing it oneself, please get in contact with our service department (see also chapter “2.5 Service”)

7.2

Safe use Particularly observe the following points when operating the clutch: –

the permissible load values and the maximum speed as specified in the drawing or catalogue may not be exceeded.

–

all safeguards must be put in place.

If the permissible load specifications are exceeded, consultation with the manufacturer is mandatory. It is very important that the friction pads be kept free from grease and oil, since otherwise insufficient coupling torque can be transmitted. When cleaning the drive unit, greasing or corrosive cleaning agents may not come in contact with the Planox® clutch. The friction surfaces of the friction discs (27) may not be cleaned with solvents such as gasoline, acetone or petroleum. When they have become covered in oil or dirtied, the friction discs must be replaced. All screw connections are to be tested at the prescribed tightening torques. Screws coming loose can cause the drive unit to fail. It is very important that the prescribed tightening torques be kept to. In order to avoid unnecessary overheating of the drive unit, a cooling down period of approx. 20 minutes should be observed after a switching-off procedure caused by a blockage.


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8

Maintenance and repair DANGER Danger of injury from rotating parts. Only carry out work on the drive unit with the machine at a standstill. For all work done on the drive unit, ensure that all drives are switched off (e.g. from the machine main switch) and are protected against accidental switching back on (e.g. by removing a fuse in the power supply or putting up a sign that says that the drive unit is being worked on).

8.1

Maintenance interval The maintenance intervals for the Planox® clutch are determined by the application conditions of the clutch. The operating behaviour of the Planox® clutch is to be monitored by the customer, and in event of deviations from normal operating behaviour or familiar operating noises, the Planox® clutch is to be inspected. Check that the rolling bearings are running quietly, and install new bearings if they are damaged. For further instructions regarding the maintenance intervals for suppliers’ parts – in particular for the control switch (130) – refer to the documentation of the corresponding suppliers.

8.2

Checking for wear Caution! Worn-out parts can result in the failure of the safety function of the clutch. If worn out, the affected parts are to be replaced. Caution! Indications of wear can be hidden by abraded particles or may not be seen if lighting is poor. Carefully clean wear parts and check them for signs of wear in a well-lit place.

8.3

Overview of wear parts For spare parts / wear items please refer to chapter “1. Product overview” You should only use original spare parts from DESCH. Non-compliance leads to the loss of all warranty claims.


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Checking related parts for wear If the friction discs (27) are worn out, the friction surfaces of the clutch hub (2), the pressure disc (4) and the inner discs (3, only in the case of models with two friction discs (27) or more) should be checked for wear and cracks, and replaced if necessary.

8.5

Servicing the friction discs.

Inspection dimension “Y” 9.5

mm

“New”

1

mm

“Worn”

The inspection is carried out with engaged clutch and when the drive is standing still. The outer discs (27) must be replaced, before they pressure ring (74) and bolts (75) are blocked.

8.6

Servicing the roller bearings. Greasing quantities and intervals can be obtained from the following table. While carrying out repair and maintenance work on the bearings, you must check that they are running quietly. The bearing must be replaced if there is damage (grinding noises). Greasing

(lifetime lubricated)

Roller bearing Pos. 55 (switching section bearing)


Roller bearing Pos. 81 (free-wheeling of wedge plate)


Roller bearing Pos. 126 (flywheel flange bearing)


Lithium saponified grease of consitency class 3: e.g.: ESSO-UNIREX N3,

Grease:

8.7

Roller bearing Pos. 42 (bell housing bearing)

Servicing the seals The seals (59, 60 + 62, 129) do not require any special maintenance. In case of repair and maintenance work on the clutch, wear items like seals and springs (17 + 46) should generally be replaced. Lightly grease the bearing and sealing surfaces of the seals before mounting. Do not damage the seals when mounting. Note the correct assembly position of the sealing lip when inserting the grooved ring seals.


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Maintaining the control switch (130) In the first month after commissioning, you must check the accumulator filling pressure of the control switch (130) on a weekly basis; after this, carry out the inspection at least every six months. At delivery, the pressure is pre-set to 15 bar. If there is a drop below 10 bar, the pressure is pre-set to 15 bar. If there is a drop below 10 bar, you must correct the pressure to 15 ±1. The complete control switch (130) must be replaced after ten years at the latest.

8.9

Repairing the Planox clutch ®

For all repair and service work on the Planox clutch the clutch must be disassembled and sent back to our headquarters in Arnsberg, or to our subsidiary DDT in Canada for overhauling. You find the addresses in Chapter 2.6 Service. DANGER Improperly performed repair work on the clutch can lead to malfunctions. Return the Planox® clutch to the factory to have it repaired. Caution! Worn-out parts can result in the failure of the safety function of the clutch. If worn out, the affected parts are to be replaced. Dismounting the entire clutch:

•

Dismantle the oil supply.

•

Relieve tension on the V-belt and remove it.

•

Disassembling the hydraulic pump

•

Secure the drive unit against falling using suitable lifting gear.

•

Remove the screws of the bell to the drive unit and extract the complete clutch from the centring of the housing.

•

Carefully set down the bell onto a suitable stable and clean surface.

•

Secure the bell housing against rolling away using straps and wedges.

Incorrect removal of the supports and constraints can lead to the drive unit slipping and crushing persons. Before complete removal of the supports and constraints, the drive unit must be secured against slipping using suitable slinging gear. •


Pack the drive unit ready for shipping and send it back to the factory.

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9

Faults and remedy

9.1

The clutch slips under load

9.2

9.3

10

Cause

Remedy

Belleville springs (17) have settled

Replace the Belleville springs

Worn-out outer disc (27)

Replace the outer disc

Grease on the friction surfaces of items 2, 3 + 4

Wash the affected steel parts with gasoline or acetone

Grease on the outer disc (279

Replace the outer disc with a new one

Control switch (130) malfunction

Check the control switch and replace it if necessary

Hub and pressure disc heat up over 120 °C while switched on Cause

Remedy

Belleville springs (17) have settled, causing the clutch to slip under load.

Replace the Belleville springs



Hub and pressure disc heat up while switched-off Cause

Remedy

Pressure disc (4) and inner discs (3) are stuck on the bolt (12)

Re-establish the axial movability of the parts 3 and 4 on the bolt (12)

Pressure disc (4) and inner discs (3) do not vent, because the oil pressure is too low

Adjust the oil pressure, so that the clutch vents again



Ordering spare parts In order to avoid confusion in ordering spare parts, the serial number or the drawing number of the clutch and the item number must always be stated. Alternatively, a specimen of the spare part concerned may be sent in. Only DESCH original spare parts must be used. Please submit spare parts orders in writing.


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11

Checking for radial and axial run-out Check for radial and axial run-out as follows: •

Check axial run-out TPM (see table 1) from flywheel to centring on engine housing using dial gauge and magnetic mounting adapter.

•

Check radial run-out (eccentricity) TRM (see table 1) from flywheel to centring on engine housing using dial gauge and magnetic mounting adapter.

•

Check axial run-out TPS (permitted 0.05 mm on 100 mm radius) from engine housing to centring on flywheel using dial gauge magnetic mounting adapter.

•

Check radial run-out TRS (permitted 0.13 mm) from engine housing to centring on flywheel using dial gauge and magnetic mounting adapter and mark the point with the greatest deviation.

•

Check radial run-out TRF (permitted 0.13 mm) from engine housing to centring on flywheel using dial gauge and magnetic mounting adapter and mark the point with the greatest deviation.

•

Calculate the deviation from the centre Tm (permitted 0.2 mm) of the centres on flywheel and guide bearings as follows: Tm = TRS – TRF

Tm = TRS – TRF

2

2

Points of greatest deviation are on the same side.

Points of greatest deviation are opposite one another.

Permissible radial and axial run-outs: Housing flange size according to SAE standard Flange diameter Da (mm) Permissible radial and axial run-outs TPM TRM (mm)

6 308

5 356

4 403

3 451

2 489

1 552

0 711

00 883

0.15

0.15

0.15

0.2

0.2

0.2

0.25

0.3

Table I Clutch size

51

61

71

81

101 111 141 161 181 211 241 271 301 361 421 481 601 102 112 142 162 182 212 242 272 302 362 422 482 602 143 163 183 213 243 273 303 363 423 483 603

Permissible radial (X) axial (X1) run-

0.1 0.1 0.1 0.1 0.15 0.15 0.15 0.2 0.2 0.2 0.25 0.25 0.25 0.3 0.3 0.3 outs (mm) Table II The more precise the alignment, the more reliable the drive, and the longer the service life of the clutch. Issue: February 2014

0.3

Page 22

Eigene erstellte Stempel

INVALID! For Information Only!

Operating Manual VULASTIK L

Series:

2802

Size:

1410 ; 1610 ; 1910 ; 2210 ; 2610 ; 3010 ; 3110 ; 3410 ; 3610 ; 3710 ; 4010 ; 4310

Read the assembly manual prior to starting all tasks!

VULKAN Kupplungs- und Getriebebau ©

Bernhard Hackforth GmbH & Co. KG Heerstrasse 66 44653 Herne Tel.: +49 (0) 2325 / 922-0 Fax.: +49 (0) 2325 / 711 10 E-mail: [email protected] Internet: www.vulkan.com 0000001059 002 10.1.14

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Table of contents Table of contents

1

General

1.1 1.2 1.3 1.4 1.5 1.6 1.7

Information about the operating manual............................................... Explanation of symbols ........................................................................ Limitation of liability .............................................................................. Copyright .............................................................................................. Spare parts........................................................................................... Warranty terms..................................................................................... Customer service .................................................................................

2

Safety

2.1 2.2 2.3 2.4 2.5 2.6 2.7

Responsibility of the owner .................................................................. Personnel requirements ....................................................................... Intended use ........................................................................................ Personal protective equipment............................................................. Special dangers.................................................................................... Behaviour in the event of danger or accident....................................... Environmental protection......................................................................

3

Exploded drawing / spare parts list

4

Technical data

4.1 4.2

Consignment number ........................................................................... General ................................................................................................

5

Structure and function

5.1 5.2

Mode of operation ................................................................................ Structure of the coupling ......................................................................

6

Transport, packaging, and storage

6.1 6.2 6.3 6.4 6.5

Safety instructions for transport............................................................ Symbols on the packaging ................................................................... Transport inspection............................................................................. Packaging ............................................................................................ Preservation .........................................................................................

5 5 6 6 7 7 7

8 9 10 10 12 16 17

20 20

25 25

27 28 29 29 31 3/74


Table of contents 6.5.1 6.5.2 6.5.3 6.6 6.7

Preservation with Metacorin ................................................................. Preservation of VCI .............................................................................. Table Metacorin/VCI/Rolimeco............................................................. Transport .............................................................................................. Storage.................................................................................................

7

Assembly

7.1 7.2 7.2.1 7.2.2 7.3 7.4

Safety assembly ................................................................................... Assembly of single component............................................................. Casing installation ................................................................................ Installation of the elastic part / element ................................................ Alignment ............................................................................................. Concluding tasks and final inspection ..................................................

8

Faults

8.1 8.2 8.3 8.4

Safety faults ......................................................................................... Fault table ............................................................................................ Fault correction tasks ........................................................................... Start-up after a corrected fault..............................................................

9

Maintenance

9.1 9.2 9.3 9.4

Safety maintenance.............................................................................. Maintenance schedule ......................................................................... Maintenance tasks ............................................................................... Measures after successful maintenance ..............................................

10

Dismantling

10.1 10.2 10.2.1 10.2.2 10.3

Safety dismantling ................................................................................ Dismantling sequence .......................................................................... Dismantling elastic element / part ........................................................ Dismounting the casing ........................................................................ Disposal................................................................................................

11

Index

31 35 37 38 43

44 48 48 49 51 56

57 58 60 60

62 63 64 66

67 70 71 71 72

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1 General

1

General

1.1

Information about the operating manual This operating manual provides important instructions for handling the VULASTIK L. The prerequisite for safe work is compliance with all specified safety instructions and handling instructions. In addition the applicable local accident prevention regulations and general safety regulations must be complied with for the specific area of implementation of the VULASTIK L. The operating manual must be carefully read prior to starting any task! The operating manual is a component of the product and must be kept in the vicinity of the coupling where it is available to personnel at all times. If the VULASTIK L is provided to a third party then this operating manual must also be provided. The illustrations in this manual are provided for better presentation of the described material; these illustrations are not necessarily true to scale and may deviate slightly from the actual version of the VULASTIK L. The position numbers used in the steps correspond to the position numbers in the illustrations. This assembly manual corresponds to requirements of DIN 82079. It is subject to an ongoing review process. Subject to changs and errors.

1.2

Explanation of symbols Safety instructions are indicated by symbols in this operating manual. The safety instructions are introduced by signal words that express the scope of the hazard. The safety instructions must be strictly complied with, you must act prudently to prevent accidents, personal injury, and material damage. CAUTION! ... indicates a possible dangerous situation that can result in minor injury if it is not avoided. WARNING! ... indicates a possible dangerous situation that can result in death or serious injury if it is not avoided. DANGER! ... indicates a directly dangerous situation that will result in death or serious injury if it is not avoided.

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1 General

Prohibitory!

i 1.3

Note! ... indicates useful tips and recommendations, as well as information for efficient and trouble-free operation.

Limitation of liability All information and instructions in this operating manual have been provided under due consideration of applicable guidelines, the current state of technology, as well as our many years of experience. The manufacturer assumes no liability for damage due to: • • • • • •

Failure to comply with the instructions in the operating manual Non-intended use Deployment of untrained personnel Unauthorized conversions Technical changes Use of non-approved spare parts

The actual delivery condition can vary from the explanations and graphic representations provided in this manual in the case of special versions, if supplemental order options are desired, or on the basis of the latest technical changes. The agreed obligations in the delivery contract, the general terms and conditions, as well as delivery conditions of the manufacturer, and the statutory regulations valid at the time the contract was concluded, apply.

1.4

Copyright Treat this operating manual with confidentiality. It has been exclusively prepared for personnel working with the VULASTIK L coupling. Provision of the operating manual to third-parties without written consent from the manufacturer is prohibited.

i

Note! The content, texts, drawings, graphics, and other presentations are protected by copyright and are subject to commercial property rights Any improper use is punishable.

6/74


1 General Duplication in any form - including excerpts - as well as exploitation and/ or communication of the content are not permitted without a written declaration of consent from the manufacturer. Actions to the contrary make damage compensation mandatory. We reserve the right to enforce additional claims.

1.5

Spare parts WARNING! Incorrect or defective spare parts can cause damage, malfunction, or total failure; they can also impair safety. Therefore: •

Only use manufacturer's original spare parts.

Spare parts Order via authorized dealers or directly from VULKAN customer service. See section "Customer service" for the contact address. Specify the following information when ordering spare parts: • • •

1.6

Order number or consignment number Drawing number Parts list number

Warranty terms The warranty terms are included in the manufacturer's terms and conditions.

1.7

Customer service Our customer service organization is available for technical information. The responsible contact is always available at the following contact address: Customer service: VULKAN Kupplungs- und Getriebebau B. Hackforth GmbH & Co. KG Heerstrasse 66 44653 Herne Germany Tel.:+49 (0) 2325 / 922-0 Fax:+49 (0) 2325 / 711 10 Mobile: +49 (0) 178 / 8 922 179 In addition our employees are always interested in new information and experiences associated with the application that could be valuable for the improvement of our products.

7/74


2 Safety

2

Safety

2.1

Responsibility of the owner This section provides an overview of all the important safety aspects for optimal protection of personnel, as well as for safe and trouble-free operation. Significant hazards can occur if the handling instructions and safety instructions in this manual are not complied with. The VULASTIK L coupling is used in commercial operation. Consequently the owner of the VULASTIK L coupling is subject to legal industrial safety obligations. In addition to the industrial safety instructions in this operating manual, generally valid safety and accident protection guidelines, and environmental protection guidelines must be heeded and complied with for the area of implementation of the VULASTIK L coupling. The following particularly applies in this regard: •

•

• •

• •

The owner must inform himself of applicable occupational health and safety regulations, and in a hazard analysis identify other hazards that may exist at the installation site of the coupling due to the special work conditions. The owner must convert this information relative to hazards into operating instructions for operation of the coupling. The owner must ensure during the entire implementation period of the coupling that the operating instructions created by the owner correspond to the current state of legislation, and if necessary the owner must adapt these operating instructions. The owner must clearly regulate and specify responsibilities for installation, operation, maintenance, and cleaning. The owner must ensure that all employees who handle the coupling have read and understood the operating manual. In addition, customer must train personnel and inform personnel of the hazards at regular intervals. The owner must attach a distance protection fixture in the form of a coupling protector before commencing operation of the system. The owner must provide the required protective equipment for personnel.

Moreover the owner is responsible for ensuring that the coupling is always in technically faultless condition; consequently the following applies: • •

The owner must ensure that the maintenance intervals described in this operating manual are complied with. The owner must have all safety devices inspected regularly for function and for completeness.

8/74


2 Safety

2.2

Personnel requirements Qualifications WARNING! Danger of injury due to insufficient qualification! Improper handling can cause serious injury or material damage. Therefore: •

Only have activities performed by personnel who are qualified to perform these activities.

The following qualifications are cited in the operating manual for the various activity areas. •

•

Instructed person is a person who has been instructed by the owner relative to the tasks assigned to him and the possible dangers associated with improper behaviour. Qualified personnel are personnel who, due to their qualified training, skills, and experience, as well as knowledge of the applicable regulations, are capable of executing the tasks assigned to them and of recognizing possible hazards and avoiding them on their own.

Only persons from whom it can be expected that they reliably execute their work are considered as personnel. Persons whose capability to react is impaired, for instance through drugs, alcohol, or medication, are not approved. •

Comply with age-specific and job-specific regulations that are applicable at the installation site when selecting personnel. Unauthorized persons WARNING! Danger for unauthorized persons! Unauthorized persons who do not satisfy the requirements described here are not aware of the hazards in the work area. Therefore: •

Keep unauthorized persons away from the work area.

•

If in doubt, speak to these persons and instruct them to leave the work area.

•

Interrupt work as long as unauthorized persons are in the work area.

9/74


2 Safety 2.3

Intended use The VULKAN coupling is a torsional elastic rubber coupling that offsets the radial, axial, and angular displacement of connected aggregates. It is designed for use in ship generator drives, gear unit drives, compressor drives, pump drives, and blower drives that have a ductility requirement. It has been especially developed for a particular application case and can only be used for a different application after consultation with the manufacturer. WARNING! Danger due to non-intended use! Any use that extends beyond intended use and/or other use of the coupling can cause hazardous situations. Therefore: •

Only use the coupling as intended.

•

Only place the coupling in service after complete assembly in accordance with the instructions in this operating manual.

•

Strictly comply with all instructions in this operating manual.

•

Particularly refrain from the following uses of the coupling. They are considered as non-intended use:

•

Use outside of the originally intended application case.

•

Overloading the coupling by exceeding the limit values specified in the technical data.

•

Use of a coupling that does not bear an Ex designation, and thus is not designed for use in explosive atmospheres, in the Ex area.

Claims of any type due to damage arising from non-intended use are excluded. The owner is solely liable for all damage in the case of non-intended use.

2.4

Personal protective equipment Wearing of personal protective equipment is required for work, to minimize health hazards. • •

When performing the task always wear the personal protective equipment that is required for the task. Follow the instructions that have been posted in the work area.

Always wear the following during all tasks: •

Protective work clothing is tight-fitting work clothing with low resistance to tearing, with tight sleeves, and without projecting parts. It is primarily used to protect against entanglement by moving machine parts. Do not wear rings, chains, or other jewellery.

10/74


2 Safety

•

Hard hat to protect against falling and flying parts and materials.

•

Safety footwear for protection against heavy falling parts and slipping on slippery surfaces.

Special protective equipment is required when executing special tasks. Special reference is made to this equipment in the specific sections of this manual. This special protective equipment is explained below: •

Light respiratory protection for protection against harmful dusts.

•

Protective goggles to protect eyes from flying parts and liquid splashes.

11/74


2 Safety

2.5

•

Protective gloves to protect hands from friction, abrasion, puncture wounds, or deeper injuries, as well as from contact with hot surfaces.

•

Chemical-resistant protective gloves to protect hands from aggressive substances. Check protective gloves for leaks prior to use. Clean the gloves before pulling them off; store them in a well-ventilated location.

Special dangers Residual risks that have been determined based on a risk assessment are cited below. Follow the safety instructions listed here and the warning instructions in the other sections of this manual to reduce health hazards and to avoid dangerous situations.

WARNING! Life-threatening hazard - High dead weight! The coupling has an extremely high dead weight. A life-threatening hazard due to crushing exists if the coupling rolls off or falls down. Therefore: •

Always safeguard the coupling against rolling off.

•

Carefully supervise the lifting processes and transport.

•

Only use the transport methods described in the "Transport" section.

•

Secure the coupling parts that will be loosened against falling, before loosening any threaded joints.

•

Physical lifting processes involving a reference weight in excess of 25 kg should only be executed with two persons.

12/74


2 Safety

WARNING! Life-threatening hazard - High elastic forces! The rubber elements and the membrane can accumulate extreme quantities of energy when they are deflected. Sudden loosening of obstructions can cause high energy movements of coupling parts, and in the process cause life-threatening injury. Therefore: •

Prior to working on the coupling ensure that it is force-free and that the resilient elements are not deflected.

•

For tasks that require deflection of resilient elements only employ the work methods described in this manual. Only use tools and clamping devices that are designed for high forces.

•

Only specialized personnel familiar with the installation should select the thrust bearing required for deflection of the membrane assemblies.

WARNING! Life-threatening danger and danger of material damage due to incomplete or incorrect assembly! If there is a mechanical failure of components and incomplete or incorrect assembly, coupling parts can be thrown out at high speed due to rotation. This poses a life-threatening hazard and danger of material damage. Therefore: •


•

Only operate the coupling within the protective fixture described in the "Assembly" section. This protective fixture must be installed by the owner.

•

After working on the coupling, ensure that all bolt connections are firmly tightened in accordance with the specified tightening torques.

13/74


2 Safety

CAUTION! There is a danger of stumbling due to fouling and loose objects! Fouling and loose objects on the ground pose slipping and stumbling hazards and can cause severe injuries. Therefore: •

Always keep the work area clean.

•

Remove objects that are not being used.

•

Mark stumbling hazards clearly.

•

Make provisions for good lighting.

CAUTION! Material damage if configured incorrectly! If the coupling is configured incorrectly then extremely high dynamic forces can be transferred to the shafts and to the adjacent machine components and they could be damaged. Therefore: •

Prior to installation ensure that all characteristic values specified for the application in the "Technical data" section are correct.

•

Only use the coupling in the application for which the coupling is originally designed by the manufacturer.

14/74


2 Safety

WARNING! There is a fire hazard and explosion hazard posed by highly flammable corrosion-protection fluid and fumes! Liquid corrosion protection and its outgassing, when combined with air, form an explosive mixture and can cause serious or fatal injuries if ignited. Therefore: •

Do not smoke in the work area when unpacking the coupling and removing the corrosion preventative.

•

Do not handle open flame or ignition sources.

•

Ensure measures that prevent electrostatic charging.

•

Have fire extinguishers (CO2, powder or foam) on hand.

•

Do not extinguish with a water jet; water mist is suitable.

•

Initiate safety measures to prevent the accumulation of flammable fumes in lower positioned areas or enclosed areas.

•

Stop work immediately if there is a fire. Leave the danger zone until it is safe to resume work.

WARNING! Toxic hazard if fumes or aerosols are inhaled or if the corrosion preventative is ingested! Corrosion preventative contains harmful components that can result in poisoning and skin irritations. Repeated contact can cause skin dryness and cracking. Therefore: •

Comply with the instructions in the manufacturer's safety data sheet.

•

Only unpack the coupling in well-ventilated areas.

•

Only use the corrosion preventative in well-ventilated areas.

•

If inhaled get the person affected to fresh air immediately. Seek medical attention.

•

If ingested summon a physician immediately. Thoroughly rinse mouth out with water.

•

Avoid contact with skin and eyes: When working wear chemical-resistant protective gloves and protective goggles with side protection. After work wash thoroughly and use skin-care cream.

•

If there is skin or eye contact rinse immediately and thoroughly with water. Seek medical attention.

•

Do not eat, drink, or smoke when working with the substance. 15/74


2 Safety

CAUTION! Health hazard due to contact with VCI foil! VCI coil contains harmful components. Repeated or longer skin contact can dissolve skin fat and cause dermatitis. Therefore:

2.6

•


•

Avoid contact with skin and eyes.

•

Apply suitable skin protection cream prior to working on elastic elements.

•

When working wear chemical-resistant protective gloves and protective goggles with side protection.

•

After work wash thoroughly and use skin-care cream.

•

After eye contact thoroughly rinse eyes for approximately 15 minutes. Seek medical care immediately.

•

After skin contact wash immediately with water and soap.

•

Do not eat, drink, or smoke when working with the substance.

Behaviour in the event of danger or accident Preventative measures • • • •

Always be prepared for accidents or fire! Keep first-aid supplies (first-aid kits, blankets etc.) and fire extinguishers close at hand. Familiarise personnel with accident alarms, first-aid kits, and rescue equipment. Keep access routes clear for rescue vehicles

Measures in the event of accident • • • • • •

Immediately activate the emergency stop. Initiate first-aid measures. Get people out of the danger zone. Inform those responsible at the implementation site. Alert emergency medical services. Keep rescue routes clear.

16/74


2 Safety 2.7

Environmental protection CAUTION! Environmental hazard due to incorrect handling! Incorrect handling of environmentally hazardous substances, particularly improper disposal, can cause significant environmental damage. Therefore: •

Always comply with the following warnings.

•

If environmentally harmful substances should inadvertently get into the environment, initiate suitable measures immediately. If in doubt notify the responsible municipal authority about the damage.

CAUTION! Corrosion preventatives are hazardous to water! This substance is toxic and should not get into the soil, water, or drainage systems. Therefore: •

Do not dispose of with household waste.

•

Dispose of in accordance with government agency regulations.

•

If the substance is inadvertently released then it must be dammed in and bound with absorbing agents. Do not use spark-forming auxiliary materials to dam-in; do not add absorbing agents (e.g. sand, dirt, or universal binders).

WARNING! Fire hazard due to spark-producing auxiliary material! When handling corrosion preventative there is a fire hazard due to sparking. Therefore: •

Do not use metallic and spark producing tools.

17/74


2 Safety

CAUTION! VCI foil is slightly hazardous to water! VCI foil has an irritating effect. It is slightly hazardous to water and should not get into drainage systems, surface water or ground water. Therefore: •


•

If it penetrates into drainage systems, bodies of water, or soil, notify the responsible authorities immediately.

•


CAUTION! Polyisoprene-based rubber mixtures! Rubber mixtures are part of the basic element of the elastic coupling. They contain the heavy metal zinc as a formula component. This substance is toxic and should not get into the soil, water, or drainage systems. Disposal: •

Rubber mixtures should not be disposed of with household waste.

•

Disposal must be executed in accordance with government agency regulations (waste code EAK 070299).

CAUTION! Lubricants, such as greases and oils, contain toxic substances! These should not get into the soil, water, or drainage systems. Therefore: •

Disposal must be executed by a specialized disposal company.

18/74


3 Exploded drawing / spare parts list

3

Exploded drawing / spare parts list

6

Fig. 3-1

Item

Designation

1

Housing

6

Elastic element Tbl. 3-1

19/74


4 Technical data

4

Technical data

4.1

Consignment number The consignment number is specified on the outside of the casing. It has been stamped on.

Fig. 4-1

4.2

General

Abbreviation

Description

TKN

Nominal torque

nK max.

Maximum permissible rotational speed

ΔKa

Permissible axial shaft displacement

ΔKr‘

Permissible radial coupling displacement/see list technical data Tbl. 4-1

20/74


4 Technical data Technical data

Nominal torque Model

TKN1) kNm

Permissible rotational speed

Permissible radial coupling displacement

nKmax2)

ΔKr2)

1/min

mm

1411

0.40

5300

1.0

1412

0.50

5300

1.0

1413

0.50

5300

1.0

1418

0.50

5300

1.0

1611

0.63

4100

1.0

1612

0.80

4100

1.0

1613

0.80

4100

1.0

1618

0.80

4100

1.0

1911

1.00

3600

1.0

1912

1.25

3600

1.0

1913

1.25

3600

1.0

1918

1.25

3600

1.0

2211

1.60

3200

1.5

2212

2.00

3200

1.0

2213

2.00

3200

1.0

2216

2.00

3200

1.0

2218

2.00

3200

1.0

221 A

2.00

3200

1.0

2611

2.50

2700

1.5

2612

3.15

2700

1.0

2613

3.15

2700

1.0

2616

3.15

2700

1.0

21/74


4 Technical data


TKN1) kNm



nKmax2)

ΔKr2)

1/min

mm

2618

3.15

2700

1.0

261 A

3.15

2700

1.0

3011

4.00

2500

1.5

3012

5.00

2500

1.0

3013

5.00

2500

1.0

3016

5.00

2500

1.0

3018

5.00

2500

1.0

301 A

5.00

2500

1.0

3411

6.30

2500

1.5

3412

8.00

2500

1.0

3413

8.00

2500

1.0

3416

8.00

2500

1.0

3418

8.00

2500

1.0

341 A

8.00

2500

1.0

3711

8.00

2500

1.5

3712

10.00

2500

1.0

3713

10.00

2500

1.0

3716

10.00

2500

1.0

3718

10.00

2500

1.0

371 A

10.00

2500

1.0

4011

10.00

2500

1.5

4012

12.50

2500

1.0

4013

12.50

2500

1.0

4016

12.50

2500

1.0

22/74


4 Technical data


TKN1) kNm



nKmax2)

ΔKr2)

1/min

mm

4018

12.50

2500

1.0

401 A

12.50

2500

1.0

4311

16.00

2500

1.5

4312

20.00

2500

1.0

4313

20.00

2500

1.0

4316

20.00

2500

1.0

4318

20.00

2500

1.0 Tbl. 4-2

1

) The application factors L, M and C must be taken into account. ²) The operating status of the plant can make correction / reduction of the specified values (speed / permissible coupling displacement) necessary. See the explanation in the technical data (ETD-1): http://www.vulkan.com/vulkan_couplings/downloads.htm See the current product catalogue for additional technical data. Dimensions/masses: Version A Assembly

Diameter

Installed mass

Mass

D1 (mm)

L1 (mm)

m[kg]

1410

263,50

9,00

2,70

1610

314,40

11,00

4,00

1910

352,40

14,70

5,80

2610

466,70

18,40

14,53

3010

466,70

16,40

18,80

3110

466,70

57,00

39,00

3210

466,70

45,00

22,50

23/74


4 Technical data

Assembly

Diameter

Installed mass

Mass

D1 (mm)

L1 (mm)

m[kg]

3410

571,50

49,00

46,00

3610

571,50

25,00

44,10

3710

571,50

29,00

42,80

4010

673,10

54,00

76,60

4310

673,10

45,00

98,86 Tbl. 4-3

See the current product catalogue for additional technical dimensions/ masses/versions. Version A

Fig. 4-2

24/74


5 Structure and function

5


5.1

Mode of operation The VULKAN VULASTIK L coupling is a torsion-flexible rubber coupling that compensates for the radial, axial and angular shaft displacement of the connected machinery. The ring-shaped rubber elements ensure the torque transmission and are subjected to rotary thrust.

5.2

Structure of the coupling Elastic element / part The elastic element is the basic element of the coupling. The elastic element is used to tune torsional vibration behaviour and to compensate radial and axial shaft displacement. Gearing on the outer diameter enables connection with the flange casing.

Fig. 5-1

Casing The casing connects the elastic element (part) to the drive-side flywheel via an axial spline. It sits in the centring element of the drive-side plant and is held in place with a threaded joint. This design enables compensation of axial shaft displacements.

25/74



Fig. 5-2

26/74


6 Transport, packaging, and storage

6


6.1

Safety instructions for transport CAUTION! Improper transport can cause damage! Significant damage can occur if the device is transported improperly. Therefore: •

Proceed with caution when unloading packages at delivery, as well as for inner-company transport, and comply with the symbols and instructions on the packaging.

•

Only use the intended attachment points.

•

Only remove the packaging just prior to assembly.

•

Note the markings on the packages.

WARNING! Life-threatening danger due to suspended loads! When lifting loads there is a life-threatening hazard due to falling parts or parts swinging out of control. Therefore: •

Never step under suspended loads.

•

Comply with the instructions concerning the intended attachment points.

•

Do not attach on projecting machine parts or on the eyes of installed components. Ensure that the sling gear is securely seated!

•

Only use approved hoists and sling gear with sufficient bearing capacity.

•

Do not use rope and straps that are torn or frayed.

•

Do not place ropes and straps on sharp edges and corners; do not knot or twist ropes and straps.

27/74



WARNING! Danger of falling due to eccentric center of gravity! Packages can have an eccentric center of gravity. If attached incorrectly the packages can tip and cause life-threatening injuries. Therefore: •

Note the markings on the packages.

•

Attach the crane hook in such a manner that it is located above the center of gravity.

•

Carefully lift and see if the load tips. If necessary change the attachment.



•


•


•


•


WARNING! Danger of injury due to loosely mounted housing! The casing is loosely mounted on the spline of the elastic part and it is not secured against falling. There is an injury hazard if the housing falls. Therefore:

6.2

•

Secure the housing against falling.

•


•


•


Symbols on the packaging Attachment point 28/74


6 Transport, packaging, and storage Only place sling gear (attachment chain, lifting strap) at the points marked with this symbol.

Fig. 6-1

Weight, attached load Indicates the weight of packages. Handle the marked package in accordance with its weight.

Fig. 6-2

6.3

Transport inspection Check delivery immediately upon receipt to ensure that delivery is complete, and to identify any transport damage. Proceed as follows if there is apparent external damage: • • •

i 6.4

Do not accept the delivery or only accept it with reservation. Note the extent of transport damage on the transport documents or on the transport company's delivery ticket. Submit a complaint.

Note! Report any defect as soon as it is detected. Claims for damage compensation can only be enforced during the applicable periods for giving notice of lack of conformity.

Packaging About the packaging

29/74


6 Transport, packaging, and storage Individual packed goods are packaged according to the expected transport conditions. Environmentally-friendly materials have been used exclusively for the packaging. Packaging should protect the specific components from transport damage, corrosion, and other damage until assembly. Consequently do not destroy the packaging and only remove it just before assembly.

Fig. 6-3

Fig. 6-4

Handling packaging materials Dispose of packaging materials in accordance with the respectively valid statutory regulations and local guidelines.

30/74



CAUTION! Improper disposal causes environmental damage! Packaging materials are valuable raw materials and in many cases they can be reused, or they can be effectively treated and recycled. Therefore: •

Dispose of packaging materials in an environmentally responsible manner.

•

Comply with locally applicable disposal guidelines. If necessary, commission a specialized company to dispose of packaging.

6.5

Preservation

6.5.1

Preservation with Metacorin CAUTION! Material damage due to improper removal of the corrosion preventative! Mechanical removal of the corrosion preventative (e.g. with abrasive agents or tools) can damage surfaces and fit. Therefore: •

Use a suitable solvent or alkaline cleaning agents.

CAUTION! Corrosion preventatives are hazardous to water! This substance is toxic and should not get into the soil, water, or drainage systems. Therefore: •

Do not dispose of with household waste.

•


•

If the substance is inadvertently released then it must be dammed in and bound with absorbing agents. Do not use spark-forming auxiliary materials to dam-in; do not add absorbing agents (e.g. sand, dirt, or universal binders).

31/74



WARNING! Fire hazard due to spark-producing auxiliary material! When handling corrosion preventative there is a fire hazard due to sparking. Therefore: •

Do not use metallic and spark producing tools.

WARNING! Toxic hazard if fumes or aerosols are inhaled or if the corrosion preventative is ingested! Corrosion preventative contains harmful components that can result in poisoning and skin irritations. Repeated contact can cause skin dryness and cracking. Therefore: •


•


•

Only use the corrosion preventative in well-ventilated areas.

•

If inhaled get the person affected to fresh air immediately. Seek medical attention.

•

If ingested summon a physician immediately. Thoroughly rinse mouth out with water.

•

Avoid contact with skin and eyes: When working wear chemical-resistant protective gloves and protective goggles with side protection. After work wash thoroughly and use skin-care cream.

•

If there is skin or eye contact rinse immediately and thoroughly with water. Seek medical attention.

•


CAUTION! Solvents are a health hazard! Solvents are harmful and can damage mucous membranes. Therefore: •

Only use substantially solvent-free agents.

•

Wear chemical-resistant protective gloves and protective goggles.

•

Only use solvents in well-ventilated areas.

32/74



CAUTION! Material damage due to solvent! Solvents can damage the rubber elements! Therefore: •

Do not bring the rubber elements into contact with solvents.

Preservation of steel and cast parts with Metacorin 835 and Metacorin 850 The following types of steel parts are generally protected against corrosion with the corrosion preventative METACORIN 835/850: For steel and cast parts on surfaces and stamped images treated to finish dimension Metacorin 835 offers sufficient protection in case of: • •

dry indoor storage: more than 12 months outdoor storage under a roof: 6 months

The layer thickness of the preservation agent is 4 - 6 µm. Metacorin 850 offers sufficient protection in case of: • •


The layer thickness of the preservation agent is 5 - 8 µm. Cleaning To clean off the Metacorin 835 corrosion preventative film we recommend spraying or immersing in an aqueous-alkaline solution. The cleaning process should generally be supplemented by mechanical cleaning.

i

Note! Always use lint-free cloths for cleaning.

VULKAN uses METACLEAN 772 for this purpose. This is an aqueous cleaner with good anti-corrosion protection for 2-3 days. AVILUB METACLEAN 772 and AVILUB METACORIN 835/850 can be purchased from the manufacturer Bantleon. 33/74


6 Transport, packaging, and storage www.bantleon.de

i

Note! The connection surfaces and bores are preserved with corrosion preventative or the coupling is packed in VCI foil. Before installing the coupling, use cleaner to clean surfaces that have been treated with corrosion preventative.

i

Note! Comply with the safety data sheets for Metacorin and VCI foil (www.bantleon.de). Example for Metacorin:

Fig. 6-5

34/74


6 Transport, packaging, and storage 6.5.2

Preservation of VCI CAUTION! Health hazard due to contact with VCI foil! VCI coil contains harmful components. Repeated or longer skin contact can dissolve skin fat and cause dermatitis. Therefore: •


•

Avoid contact with skin and eyes.

•

Apply suitable skin protection cream prior to working on elastic elements.

•

When working wear chemical-resistant protective gloves and protective goggles with side protection.

•

After work wash thoroughly and use skin-care cream.

•

After eye contact thoroughly rinse eyes for approximately 15 minutes. Seek medical care immediately.

•

After skin contact wash immediately with water and soap.

•


CAUTION! VCI foil is slightly hazardous to water! VCI foil has an irritating effect. It is slightly hazardous to water and should not get into drainage systems, surface water or ground water. Therefore:

i

•


•

If it penetrates into drainage systems, bodies of water, or soil, notify the responsible authorities immediately.

•


Note! Do not treat elastomers and rubber parts with the corrosion preventative. Preservation of elastomer will void the warranty. Preservation with VCI 126 foil As additional transport packaging VULKAN prefers Cortec VCI-126 foils (manufactured by Bantleon: www.bantleon.de). For medium- and largesized components, entire sets are used.

35/74


6 Transport, packaging, and storage These sets include: • • • •

i

ready-made Cortec-VCI covers cut to size for the particular component, Cortec-VCI foil pre-cut for the bottom, VCI dispenser in the form of impregnated Cortec-VCI-PUR foam, Small parts are packaged in VCI-126 continuous foil or in VCI bags and other VCI-126 foil products. It may be necessary to supplement this with pre-cut VCI foam.

Note! The VCI foil used by VULKAN is PE foil with the VCI additive as vapourphase inhibitors. The inhibitors emerge from the foil in the form of vapour, saturate the enclosed air space and adhere to the bare metal surfaces as invisible, monocular films. They can also reach hard-to-access areas. When used as specified, they provide protection of 2-5 years with an airtight seal. Do not allow the VCI foil to become damaged! If the VCI foil is not replaced immediately after being damaged, VULKAN will assume no liability for any adverse effects on the coupling as a result of corrosion!

i

Note! Comply with the safety data sheets (www.bantleon.de). • •

The VCI foil fulfils the requirements of the standard TRGS 615, paragraph 5.1. The VCI foil is reusable and recyclable. Dispose of in landfill (household trash) or by burning.

Fig. 6-6

36/74



Table Metacorin/VCI/Rolimeco Overview of corrosion protection with Metacorin/VCI

Standard corrosion protection Membrane assemblies up to 6 months (stored outdoors under a roof)

Additional corrosion protection Steel, cast and vulcanised steel and cast parts > 12 months (stored indoors in a dry room)

Metacorin 850, dry layer thickness min. 5 µm / max. 8 µm

Rolimeco 397, dry layer thickness min. 4 µm / max. 6 µm

Parts in VCI foil or aluminium foil; inside with VCI foam dispenser, if necessary




Parts in VCI foil; inside with VCI foam dispenser, if necessary




Parts in VCI foil




Not necessary!

Standard corrosion protection Steel and cast parts up to 6 months (stored outdoors under a roof)

Standard corrosion protection Vulcanised steel and cast parts up to 4 months (stored outdoors under a roof)

See freight overseas, tropical and sub-tropical regions


Intercontinental shipping points

within Europe Short hauls, domestic, bordering states per carrier

Tbl. 6-1

37/74



6.6

Transport Transporting pallets with the crane Packages that are attached to pallets can be transported with a crane under the following conditions: • •

Crane and lifting gear must be designed for the weight of the packages. The operator must be authorized to operate the crane.

Attachment: • • • •

Attach ropes, straps or multi-point suspensions to the pallet according to the illustration and ensure that they cannot slip. Ensure that the packages cannot be damaged by the sling gear. Use other sling gear if necessary. If there is an eccentric centre of gravity ensure that the pallet cannot tip. Start the transport.

Fig. 6-7

Transporting pallets with the forklift Packages that are attached to pallets can be transported with a forklift under the following conditions: • •

The forklift must be designed appropriately for the weight of the transport units. The operator must be authorized to operate the forklift.

38/74


6 Transport, packaging, and storage Attachment • • • •

Drive the forklift with the forks between or under the spars. Drive in the forks until they protrude on the opposite side. If there is an eccentric centre of gravity ensure that the pallet cannot tip. Lift the package and start the transport.

Fig. 6-8

Transporting assemblies with a crane The coupling components (delivery assemblies) can be transported with a crane under the following conditions: • •

Crane, hoists, and attachment gear must be designed for the weight of the coupling components. The operator must be authorized to operate the crane.

CAUTION! Using the wrong sling gear can damage the rubber body The rubber body can be damaged if looped with rope. Therefore: •

Never place rope around the rubber body for attachment.

•


Attachment • • •

Attach rope or straps on the attachment points of the coupling parts. Ensure that the coupling hangs straight; pay attention to possible eccentric centre of gravity. Start the transport.

39/74


6 Transport, packaging, and storage Elastic element Attach the elastic element by means of a textile load sling and connect to the lifting gear.

Fig. 6-9

Transporting the casing Attach the casing via a textile load sling and connect it to the lifting gear.

Fig. 6-10

Storage of packages

40/74


6 Transport, packaging, and storage Only store packages under the following conditions: • • • • • • • •

• •

i

Do not store outdoors. Store in a dry and dust-free location. Do not expose to aggressive media. Protect from direct sunlight. Avoid mechanical vibration. Storage temperature: 15 to 25°C. Relative humidity: Max. 60% For longer periods of storage (> 3 months) regularly check the general status of all parts and the status of the packaging. Touch up or reapply anti-corrosion agents as needed. If stored for longer than 3 years, a repetition of the static test of the elastic elements is required. For storage longer than 5 years the technical data, such as dynamic torsion spring stiffness and static angle of rotation characteristic of the elastic elements, must be checked.

Note! Under certain circumstances storage instructions are on the packages that extend beyond the requirements cited here. Comply with these instructions accordingly. CAUTION! Material damage if stored incorrectly! Incorrect storage of the elastic elements can cause irreversible deformation of the elastomer. The consequence is uncontrolled torsional oscillation that can destroy the elastic element. Therefore: •

Store the elastic element horizontally.

•

Do not stress the elastic element axially, e.g. by stacking additional weights.

•

Do not set up the elastic element diagonally or on one side.

Storing the elastic elements

41/74



Fig. 6-11

Fig. 6-12

42/74



Fig. 6-13

6.7

Storage CAUTION! Material damage if stored incorrectly! Incorrect storage of the elastic elements can cause irreversible deformation of the elastomer. The consequence is uncontrolled torsional oscillation that can destroy the elastic element. Therefore: •

Store the elastic element horizontally.

•

Do not stress the elastic element axially, e.g. by stacking additional weights.

•

Do not set up the elastic element diagonally or on one side.

43/74


7 Assembly

7

Assembly

7.1

Safety assembly DANGER! There is an injury hazard if the device is not installed and commissioned properly! Improper assembly and commissioning can cause serious injury or material damage. Therefore: •

Prior to starting the tasks ensure that there is adequate free space for assembly.

•

Handle open, sharp-edged components carefully.

•

Ensure order and cleanliness at the installation location! Parts and tools that are lying loose or on top of each other are accident hazards!

•

Mount components properly. Maintain the prescribed bolt torque and fastening torque.

•

Secure the components so that they do not fall down or fall over.

Safety personnel • •

Only trained, specialized personnel should perform assembly work. If the customer desires assembly can also be executed by Vulkan employees.

Personal protective equipment Wear the following protective gear for all assembly and commissioning tasks: • • • •

i

Protective work clothing Hard hat Safety footwear Protective gloves

Note! The warnings in this section make special reference to additional protective equipment that is required for certain tasks.

44/74


7 Assembly

WARNING! There is an injury hazard if the device is not installed and commissioned properly! Commissioning Improper assembly and commissioning can cause serious injury or material damage. Therefore: •


•


•


•


•


DANGER! Life-threatening danger if restarted without authorization! When installing there is danger of the energy supply being switched on without authorization. This poses a life-threatening hazard for persons in the danger zone. Therefore: •

Prior to starting the tasks switch off all energy supplies and safeguard them from being switched on again.

•

If combustion motors supply the motive power then the safety instructions and the instructions for switching off and safeguarding against restart in the assembly manuals provided by the manufacturers must be complied with.

45/74


7 Assembly

WARNING! Life-threatening hazard - High elastic forces! The rubber elements can store extremely high levels of energy, when they are deflected. Sudden loosening of obstructions can cause high energy movements of coupling parts, and in the process cause lifethreatening injury. Therefore: •


•




•


•


•


•


46/74


7 Assembly

WARNING! Life-threatening danger due to suspended coupling parts! When lifting coupling parts a life-threatening hazard is posed by such parts falling or swinging out of control. Therefore: •

Never step under suspended coupling parts.

•


•

Do not attach sling gear to projecting machine parts or to the lugs of attached components; ensure that the sling gear is firmly seated.

•


•


•


WARNING! There is an injury hazard due to swinging coupling parts during the lifting process! Coupling parts can swing to the side and cause life-threatening injury when they are lifted from and lowered to the floor. Therefore: •

When lifting and lowering do not position yourself in the direct vicinity of the coupling parts and maintain a safety distance.

•

Look for safe possibilities of avoiding this hazard when lifting and lowering.

•

Carefully lift and observe the behaviour of the suspended load.

•


•


•


•


•


Always make sure to perform the assembly steps in the sequence described here.

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7 Assembly

WARNING! Life-threatening danger due to incorrect assembly Incorrect assembly can cause life-threatening situations. Therefore: •

Strictly comply with the assembly sequence specified here.

CAUTION! Material damage due to change in the direction of rotation for used elastic elements! Elastic elements are subject to premature material wear if the original direction of rotation is changed and the parts are reused. Therefore: •

When reusing elastic elements install them in the original direction of rotation.

•

Pay attention to the markings on the elastic element and the connecting components.

CAUTION! Material damage due to improper removal of the corrosion preventative! Mechanical removal of the corrosion preventative (e.g. with abrasive agents or tools) can damage surfaces and fit. Therefore: •

i

Use a suitable solvent or alkaline cleaning agents.

Note!

All connection elements and threaded bores must be lubricated with motor oil before such elements are inserted.

7.2

Assembly of single component

7.2.1

Casing installation Mounting the casing 1. Attaching the casing (1) (see chapter "Transport"). 2. Lightly grease the centring device of the flywheel (S). 3. Press the casing (1) into the centring element of the flywheel (S).

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7 Assembly

i

Note! The owner must dimension the fastening elements (B) and their necessary tightening torque. 4. Bolt the casing (1) and the flywheel (S) hand-tight with the fastening elements (B). 5. Slacken the load sling and remove it. 6. Tighten the fastening elements (B) with a torque wrench in compliance with the specified torque. B

S

Fig. 7-1

7.2.2

Installation of the elastic part / element Installation of the elastic element 1. The VULKAN VULASTIK L coupling is delivered pre-assembled. The element (6) and the casing (1) are loosely put together. 2. Installation of the coupling depends on the install situation. The install situation is specified by the customer-specific connecting parts. 3. Lift the elastic element (6) into the centring element of the unit (I) and bolt it with the fastening elements (B).

i

Note! The fastening elements (B) are not included in the VULKAN scope of delivery and must be configured by the owner!

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7 Assembly

B

6 I

Fig. 7-2

4. Push the drive machine and driven machine together (see the operating manuals for the drive machine and driven machine). Ensure that the gearing of the elastic element (6) meshes flush in the gearing spaces of the casing (1). 1

Fig. 7-3

50/74


7 Assembly

WARNING! Danger of injury due to improper joining and fastening of drive machines and driven machines! Drive machines or driven machines can be placed in movement due to improper fastening and can cause severe injury. Therefore: •

Strictly follow the instructions in the operating manuals provided for the drive machine and driven machine.

•

For plants strictly follow the operating instructions issued by the owners.

5. Align the plant.

i 7.3

Note! Alignment of the plant will be described in a separate chapter!

Alignment Alignment principles The more accurate the alignment, the more effective the compensation of operational misalignments by the coupling. The VULASTIK L couplings are capable of compensating for significant displacement of the connected machines without forfeiting service life.

CAUTION! Improper alignment can cause system damage! In case of excessive misalignments, high forces can be transferred to the adjoining machine parts. Therefore: •

Make sure the system is aligned correctly.

•

If the tolerances specified here are exceeded, do not operate the system. Coordinate additional measures with the manufacturer.

To align the system, the following prerequisites must be fulfilled: • • •

The hub must be mounted. The elastic part should not be installed yet. The preservation agent applied to the connecting surfaces must be completely removed.

51/74


7 Assembly

i

Note! The tolerance values specified here are for operation in warmed-up condition. If alignment is only possible in cold condition then the specified tolerance values cannot be used. System-specific thermal expansion must be determined by the system engineer and these values must be used. Contact the manufacturer for further information. After installation of the elastic part, the alignment must be checked in warmed-up condition. Radial misalignment

Fig. 7-4

1. 2. 3. 4. 5.

Determine the dimension Xr1. Turn drive unit 180° and determine the dimension Xr2. Turn drive unit 90° and determine the dimension Xr3. Turn drive unit 180° and determine the dimension Xr4. Determine the value ΔXr according to the formula below:

52/74


7 Assembly

2

⎛ X − X r1 ⎞ ⎛ X r 3 − X r 4 ⎞ ΔX r = ⎜ r 2 ⎟ ⎟ +⎜ 2 2 ⎝ ⎠ ⎝ ⎠

2

Fig. 7-5

Axial misalignment

Fig. 7-6

1. 2. 3. 4. 5.

Determine the dimension Xa1. Turn drive unit 180° and determine the dimension Xa2. Turn drive unit 90° and determine the dimension Xa3. Turn drive unit 180° and determine the dimension Xa4. Determine the value ΔXa using the formula below (Xa corresponds to the installed dimensions):

53/74


7 Assembly

ΔX a =

X a1 + X a 2 + X a 3 + X a 4 − Xa 4

Fig. 7-7

Angular misalignment

Fig. 7-8

1. Determine the dimension of the angle gap Xw1 on the appropriate reference radius R. 2. Turn drive unit 180° and determine the dimension Xw2. 3. Turn drive unit 90° and determine the dimension Xw3. 4. Turn drive unit 180° and determine the dimension Xw4. 5. Determine the value ΔXw using the formula below:

54/74


7 Assembly

2

⎛ X − X w1 ⎞ ⎛ X w3 − X w4 ⎞ ΔX w = ⎜ w 2 ⎟ +⎜ ⎟ 2 2 ⎠ ⎝ ⎠ ⎝

2

Fig. 7-9

6. Determine maximum angle gap Xwmax according to the following formula: In this regard the maximum value for ΔXw degrees, specified below must be used.

X w max = R × tan(ΔX wGrad )

7. The measured value ΔXw must be less than or equal to the calculated value Xwmax. The determined Δ values must be within the tolerances specified below. In case the values are not within the tolerances, the elements of the system must be realigned.. If this is not successful, please contact the manufacturer. Alignment tolerances

Size

ΔXr(mm)

ΔXa(mm)

ΔX w Degrees°

X14 - X19

± 0,1

± 1,0

± 0,05

X22 - X37

± 0,2

± 1,0

± 0,05

X40 - X43

± 0,35

± 1,0

± 0,05 Tbl. 7-1

55/74


7 Assembly 7.4

Concluding tasks and final inspection 1. Tighten all threaded connections with a torque wrench in compliance with the specified torque.

i

Note! The owner must ensure that the drive-side fastening elements (not included in scope of delivery) are designed for the required tightening torque! 2. This concludes assembly of the coupling. Perform a final alignment check (see "Alignment"). 3. Ensure that the owner has attached a distance protection fixture in the form of a coupling protector before commencing operation of the system (see chapter "Owner's responsibility").

56/74


8 Faults

8

Faults

8.1

Safety faults Possible fault causes and the tasks to correct these faults are described in the following section. If faults occur more frequently, the maintenance intervals must be shortened to correspond to actual system load. Contact the manufacturer if there are faults that cannot be corrected by following the instructions below (see "Customer service"). Personnel •

The maintenance and troubleshooting tasks described here should only be performed by experts with special training, or exclusively by the manufacturer. Special reference will be made to the requirement for personal protective equipment or the requirement for experts with special training in the description of the specific fault. Personal protective equipment Wear the following protective equipment for all troubleshooting tasks: • • • •

i


Note! The warnings in this section make special reference to additional protective equipment that is required for certain tasks. WARNING! Danger of injury due to improper fault correction! Improper fault correction can cause serious injury or property damage. Therefore: •


•


•

If components have been removed, ensure that they are properly reinstalled, that all fastening elements are re-installed, and that all threaded connections are tightened with the specified bolt-tightening torque.

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8 Faults

DANGER! Life-threatening danger if restarted without authorization! When correcting faults there is danger of the power supply being switched on without authorization. This poses a life-threatening hazard for persons in the danger zone. Therefore: •


•


Behaviour in case of a fault: 1. For faults that pose an imminent hazard for personnel or assets, execute the emergency stop function immediately. 2. Determine the cause of the fault. 3. If correction of the fault requires work in the danger zone, switch off the device and safeguard it against being restarted. 4. Inform the responsible parties at the implementation site of the fault without delay. 5. Have authorized, specialized personnel correct the fault or correct it yourself depending on the type of fault.

i 8.2

Note! The fault table provided below lists personnel who are authorized to correct the fault.

Fault table

Fault

Possible cause

Fault correction

Corrected by

Cracks in the elastomer

Maintenance interval exceeded

Execute the maintenance

Specialist

Service life limit exceeded

Replace elastic element

Specialist

Inadequate coupling ventilation

Improve ventilation

Specialist

Faulty alignment

Alignment check

Specialist

58/74


8 Faults

Fault

Unusual operating noise

Increased bearing forces

Destruction of an elastic element

Possible cause

Fault correction

Corrected by

Overload

Only operate the coupling in the prescribed load range

Specialist

insufficient surface protection

Replace surface protection

Specialist

Faulty alignment

Inspection of the alignment

Specialist

incorrect installation from the flexible element or the diaphragm assembly

Check the radial runout and correct assembly errors

Specialist

Elastomer detaches from the metal


Specialist

Faulty alignment

Inspection of the alignment

Specialist

incorrect installation from the flexible element or the diaphragm assembly

Check the radial runout and correct assembly errors

Specialist



Specialist



Specialist

Service life limit exceeded


Specialist

Blocking in the system

Resolve blocking and replace elastic element

Specialist

Grounding of the ship's propeller


Specialist

Short circuit in generator operation


Specialist

Faulty synchronization in generator operation


Specialist Tbl. 8-1

59/74


8 Faults 8.3

Fault correction tasks Venting the coupling • •

•

Execution only by a specialist assigned by the owner. To prevent unnecessary and impermissible warming of the elastic elements, a suitable coupling protection element (e.g. perforated plate) with appropriate ventilation cross-sections must be selected. Ensure that applicable standards for separating spacing protection fixtures are complied with.

Alignment check • •

Execution only by a specialist. Special tools required

1. Radial measuring device 2. Axial measuring device 3. Angle measuring device

The alignment process is described in detail in the "Alignment" chapter. Replacing the elastic part •

Execution only by a specialist.

1. Dismount the elastic part (see chapter "Dismounting the elastic part"). 2. Mount new elastic part (see chapter "Mounting the elastic part"). 3. Align the plant (chapter, "Alignment"). 4. Perform final inspection (see "Concluding tasks and final inspection").

8.4

Start-up after a corrected fault After correcting the fault and before switching on, perform the following steps:

60/74


8 Faults 1. Check all previously loosened threaded unions for firm seat. 2. Ensure that all previously removed protective devices and covers have been properly installed. 3. Ensure that all tools, materials, and other equipment have/has been removed from the work area. 4. Clean the work area and remove any substances that may have escaped, such as liquids, processing material, or similar items. 5. Ensure that all system safety devices are again functioning properly. 6. Owner-installed emergency stop devices, if present, must be reset. 7. Ensure that no one is in the danger zone.

61/74


9 Maintenance

9

Maintenance

9.1

Safety maintenance Personnel •

The maintenance and troubleshooting tasks described here should only be performed by experts with special training, or exclusively by the manufacturer. Special reference will be made to the requirement for personal protective equipment or the requirement for experts with special training in the description of the specific fault. Personal protective equipment Wear the following protective equipment for all troubleshooting tasks: • • • •


WARNING! Danger of injury due to improperly executed maintenance tasks! Improper maintenance can cause serious injury or material damage. Therefore: •


•


•

If components have been removed, ensure that they are properly reinstalled, that all fastening elements are re-installed, and that all threaded connections are tightened with the specified bolt-tightening torque.

62/74


9 Maintenance

DANGER! Life-threatening danger if restarted without authorization! When correcting faults there is danger of the power supply being switched on without authorization. This poses a life-threatening hazard for persons in the danger zone. Therefore:

9.2

•


•


Maintenance schedule Maintenance tasks are described in the sections below that are required for optimal and trouble-free operation. If increased wear is detected during regular inspections, then reduce the required maintenance intervals according to the actual indications of wear. Contact the manufacturer if you have questions concerning maintenance tasks and intervals (see service address). Time Interval

Maintenance task

To be performed by:

annually

Visual inspection

Specialist

Annually after a repair has been carried out

Visual inspection

Specialist

If there is damage or malfunction

Dismantle the elastic element (after a defect has been determined)

Specialist

Tbl. 9-1

Damage or malfunction due to: • • • • •

Propeller contact Short circuit in generator operation Out-of-phase synchronization in generator operation Oscillations Emergency shut-off

63/74


9 Maintenance 9.3

Maintenance tasks Alignment check • •

Execution only by a specialist. Required special tools: • Radial measuring device • Axial measuring device • Angle measuring device The process for aligning the VULASTIK Lcoupling is described in detail in the "Alignment" chapter. Inspecting for irreversible deformations • •

Execution only by a specialist. Special tools required: • Ruler • Caliper gauge 1. Remove the coupling protection installed by the owner. 2. Turn the coupling until the marking on the element is visible and easily accessible. 3. Center the ruler over the two threaded holes and measure the permissible irreversible deformation “b” to the marking.

Fig. 9-1

4. Compare the measured value with the maximum permissible values in the table below. 5. If the maximum permissible irreversible deformation is exceeded then the elastic element must be replaced (see "Dismantling the elastic part"). 64/74


9 Maintenance Permissible permanent deformation Rubber quality 4

1

2

3

[mm]

[mm]

[mm]

[mm]

14

24

18

16

16

16

35

28

18

18

19

36

29

19

19

22

44

35

22

22

26

48

38

25

25

30

47

37

26

26

31

---

---

---

---

34

39

30

21

21

36

---

---

---

---

37

40

31

22

22

40

46

35

24

24

43

46

35

24

24

b Size

Tbl. 9-2

Permissible permanent deformation Rubber quality 6

8

A

S

[mm]

[mm]

[mm]

[mm]

14

16

16

16

22

16

18

18

18

24

19

19

19

19

24

22

22

22

22

30

b Size

65/74


9 Maintenance

Rubber quality 6

8

A

S

[mm]

[mm]

[mm]

[mm]

26

25

25

25

32

30

26

26

26

32

31

---

---

---

32

34

21

21

21

30

36

---

---

---

32

37

22

22

22

31

40

24

24

24

44

43

24

24

24

44

b Size

Tbl. 9-3

9.4

Measures after successful maintenance Execute the following steps after concluding maintenance tasks and before switching the system on: 1. Check all previously loosened threaded unions for firm seat. 2. Ensure that all previously removed protective devices and covers have been properly installed. 3. Ensure that all tools, materials, and other equipment have/has been removed from the work area. 4. Clean the work area and remove any substances that may have escaped, such as liquids, processing material, or similar items. 5. Ensure that all system safety devices are again functioning properly. 6. Owner-installed emergency stop devices, if present, must be reset. 7. Ensure that no one is in the danger zone.

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10 Dismantling

10

Dismantling

10.1

Safety dismantling • •

Only trained, specialized personnel should perform dismantling work. If the customer so desires the dismantling process can also be executed by Vulkan employees.

Wearing of personal protective equipment is required for work, to minimize health hazards. • Follow the instructions that have been posted in the work area. Always wear the following during all dismantling tasks: •

Protective work clothing is tight-fitting work clothing with low resistance to tearing, with tight sleeves, and without projecting parts. It is primarily used to protect against entanglement by moving machine parts. Do not wear rings, chains, or other jewellery.

•

Hard hat to protect against falling and flying parts and materials.

•

Safety footwear for protection against heavy falling parts and slipping on slippery surfaces.

•

Protective gloves to protect hands from friction, abrasion, puncture wounds, or deeper injuries, as well as from contact with hot surfaces.

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10 Dismantling

i

Note! The warnings make special reference to additional protective equipment that is required for certain tasks. WARNING! Danger of injury due to improper dismantling! Stored residual energy, sharp-edged components, points, and corners on and in the coupling, or on the necessary tools can cause serious injuries. Therefore: •


•


•


•

Dismantle components properly. Pay attention to the high dead weight of some of the components. If necessary use lifting equipment that is suitable and approved for the weight.

•


•

Consult with the manufacturer if there are questions.

DANGER! Life-threatening danger if restarted without authorization! When installing there is danger of the energy supply being switched on without authorization. This poses a life-threatening hazard for persons in the danger zone. Therefore: •


•

If combustion motors supply the motive power then the safety instructions and the instructions for switching off and safeguarding against restart in the assembly manuals provided by the manufacturers must be complied with. 68/74


10 Dismantling

WARNING! Life-threatening hazard - High elastic forces! The rubber elements and the membrane can accumulate extreme quantities of energy when they are deflected. Sudden loosening of obstructions can cause high energy movements of coupling parts, and in the process cause life-threatening injury. Therefore: •


•


WARNING! Life-threatening danger due to suspended loads! When lifting loads there is a life-threatening hazard due to falling parts or parts swinging out of control. Therefore: •

Never step under suspended loads.

•


•


•


•


•


69/74


10 Dismantling

WARNING! There is an injury hazard due to swinging coupling parts during the lifting process! Coupling parts can swing to the side and cause life-threatening injury when they are lifted from and lowered to the floor. Therefore:

10.2

•

When lifting and lowering do not position yourself in the direct vicinity of the coupling parts and maintain a safety distance.

•

Look for safe possibilities of avoiding this hazard when lifting and lowering.

•

Carefully lift and observe the behaviour of the suspended load.

•


•


•


•


•


Dismantling sequence Carry out the dismantling procedure in the sequence described here. WARNING! Life-threatening danger due to incorrect dismantling! Incorrect dismantling can cause life-threatening situations. Therefore: •

Strictly follow the dismantling sequence specified here.

CAUTION! Material damage due to a change in the direction of rotation when reusing elastic parts! Elastic parts are subject to premature material wear if the original direction of rotation is changed and the parts are reused. Therefore: •

If reuse is planned, check the markings on all coupling parts, if necessary affix new, easy-to-understand markings.

70/74


10 Dismantling

Prohibitory! Do not disassemble the membrane package of the membrane assembly into single parts!

10.2.1 Dismantling elastic element / part Disassembly of the elastic element 1. Push the drive machine and driven machine away from each other (see also the operating manuals for the drive machine and driven machine). 2. Attaching the elastic element (6) (see chapter "Transport"). 3. Unscrew the fastening elements (B). 4. Pull the elastic element (6) out of the centring of the unit (I), lift it out of the plant, and put it down at a safe place where there is sufficient space.

B

6 I

Fig. 10-1

10.2.2 Dismounting the casing Dismounting the casing: 1. Attaching the casing (1) (see chapter "Transport"). 2. Raise slightly until slightly tensioned. 3. Unscrew the fastening elements (B). 4. Pull the casing (1) out of the centring of the flywheel (S), lift it out of the plant and put it down in a safe place where there is sufficient space. 5. Slacken the lifting gear and remove the load sling.

71/74


10 Dismantling

B

S

Fig. 10-2

10.3

Disposal If a return or disposal agreement has not been concluded, then recycle dismantled components: if a return or disposal agreement has not been concluded, then recycle dismantled components: • • •

Dispose of rubber mixtures in accordance with governmental guidelines. Sort and dispose of the remaining components in accordance with material condition Remove fuels and auxiliary materials, as well as residual processing materials and dispose of these items in an environmentally responsible manner.

CAUTION! Improper disposal causes environmental damage! Lubricants and other auxiliary materials are subject to treatment as special waste and can cause environmental damage if they are disposed of improperly. Therefore: •

Only specialized companies should dispose of lubricants and other auxiliary materials.

Local municipal authorities or specialized disposal companies provide information on environmentally responsible disposal.

72/74


11 Index

11

Index

A

I

Accident 16 Alignment 51 Alignment check 64 Alignment - prerequisites 51 Attachment 28, 38, 39, 39

Incorrect configuration 14 Installation of the elastic element Intended use 10 Irreversible deformation 64

49

L B Behaviour in case of a fault

Liability 6 Limitation of liability

58

6

C

M

Casing 25, 48 Commissioning 45 Concluding tasks and final inspection consignment number 20 Contact 7 Copyright 6, 7 Corrosion preventative 17, 31 Corrosion protection 15, 15, 32 Customer service 7

Maintenance schedule 63 Maintenance schedule table 63 Measures after successful maintenance

56

66

O Offset - angular 54 Offset - axial 53 Offset - radial 52 Operating Manual 5 Operating manual 6, 8

D Dangers 12 Danger zone 16 Dead weight 12, 28, 46 Disassembly of the elastic element Dismantling sequence 70 Dismounting the casing 71 Disposal 72 Disposal of packaging 30

P 71

S

E Elastic element 40 Elastic element / part 25 Elastic forces 13, 69 Environmental protection 17 Explanation of symbols 5 Explosion hazard 15 Explosionszeichnung/Ersatzteilliste

Personal protective equipment 10 troubleshooting 57, 62 Personnel;troubleshooting 57, 62 Personnel requirements 9 Preservation 33, 35, 37

19

Safety assembly 45, 68 Safety instructions 5 Safety personnel 44 Solvents 32 Spare parts 7 Startup after troubleshooting 60 Storage 41, 41, 43 Storage of packages 40 Structure and function 25 Symbols on the packaging 28

F Faults 57 Fire 16 Fire extinguishers Fire hazard 15 First-aid 16

T 15

Transport 27 Transport crane 38 Transport forklift 38 Transporting the casing 40 Transport inspection 29 Troubleshooting 60, 60 73/74


11 Index U Unauthorized persons

9

V VCI foil

16, 18, 18, 35, 35

W Warranty

7

74/74

Eigene erstellte Stempel

INVALID! For Information Only!

Operating Manual VULKARDAN L

Customer:

Schottel GmbH

Order number: Consignment number: Drawing number:

1K45100071

Parts list:

Read the operating manual prior to starting all tasks!

VULKAN Kupplungs- und Getriebebau ©

Bernhard Hackforth GmbH & Co. KG Heerstrasse 66 44653 Herne Tel.: +49 (0) 2325 / 922-0 Fax.: +49 (0) 2325 / 711 10 E-mail: [email protected] Internet: www.vulkan.com 0000000944 004 3.2.15

2/56


Table of contents Table of contents

1

General

1.1 1.2 1.3 1.4 1.5 1.6

Information about the operating manual............................................... Explanation of symbols ........................................................................ Limitation of liability .............................................................................. Spare parts........................................................................................... Warranty terms..................................................................................... Customer service .................................................................................

2

Safety

2.1 2.2 2.3

Responsibility of the owner .................................................................. Intended use ........................................................................................ Special dangers....................................................................................

3

Technical data

3.1

Consignment number ...........................................................................

4


4.1 4.2

Mode of operation ................................................................................ Structure of the coupling ......................................................................

5


5.1 5.2 5.3 5.4 5.5 5.5.1 5.5.2 5.5.3 5.5.4 5.6 5.7

Safety instructions for transport............................................................ Symbols on the packaging ................................................................... Delivery status...................................................................................... Packaging ............................................................................................ Preservation ......................................................................................... General instructions ............................................................................. Table Metacorin/VCI/Rolimeco............................................................. Preservation with Metacorin ................................................................. Preservation of VCI .............................................................................. Transport .............................................................................................. Storage.................................................................................................

5 5 6 7 7 7

9 10 10

12

13 13

16 16 17 17 18 18 19 19 21 21 23

3/56


Table of contents

6

Assembly

6.1 6.2 6.3 6.4 6.5 6.6 6.7

Safety assembly ................................................................................... Preparing the coupling for installation .................................................. Mounting the disc flange ...................................................................... Mounting the coupling on the drive side............................................... Mounting the coupling on the driven side............................................. Alignment ............................................................................................. Concluding tasks and final inspection ..................................................

7

Faults

7.1 7.2 7.3 7.4

Safety faults ......................................................................................... Fault table ............................................................................................ Fault correction tasks ........................................................................... Start-up after a corrected fault..............................................................

8

Maintenance

8.1 8.2 8.3 8.4 8.5

Safety maintenance.............................................................................. Maintenance schedule ......................................................................... Maintenance tasks ............................................................................... Tightening torques................................................................................ Measures after successful maintenance ..............................................

9

Dismantling

9.1 9.2 9.2.1 9.2.2 9.2.3 9.3

Safety dismantling ................................................................................ Dismantling sequence .......................................................................... Dismounting the coupling on the driven side........................................ Dismantling the coupling on the drive side........................................... Dismounting the plate flange................................................................ Disposal................................................................................................

10

Appendix

10.1 10.2

Drawing ................................................................................................ Parts list................................................................................................

11

Index

26 28 28 29 30 30 30

31 31 33 38

39 39 40 46 47

48 48 49 49 50 51

52 53

4/56


1 General

1

General

1.1

Information about the operating manual This assembly manual provides important instructions for handling the VULKARDAN L. The prerequisite for safe work is compliance with all specified safety instructions and handling instructions. In addition the applicable local accident prevention regulations and general safety regulations must be complied with for the specific area of implementation of the VULKARDAN L. The operating manual must be carefully read prior to starting any task! The operating manual is a component of the product and must be kept in the vicinity of the coupling where it is available to personnel at all times. If the VULKARDAN L is provided to a third party then this operating manual must also be provided. The illustrations in this manual are provided for better presentation of the described material; these illustrations are not necessarily true to scale and may deviate slightly from the actual version of the VULKARDAN L. The position numbers used in the illustrations and steps correspond to the position numbers of the drawing in the Appendix. This assembly manual corresponds to requirements of DIN 82079. It is subject to an ongoing review process. Subject to changs and errors.

1.2

Explanation of symbols Safety instructions are indicated by symbols in this operating manual. The safety instructions are introduced by signal words that express the scope of the hazard. The safety instructions must be strictly complied with, you must act prudently to prevent accidents, personal injury, and material damage. CAUTION! ... indicates a possible dangerous situation that can result in minor injury if it is not avoided. WARNING! ... indicates a possible dangerous situation that can result in death or serious injury if it is not avoided. DANGER! ... indicates a directly dangerous situation that will result in death or serious injury if it is not avoided.

5/56


1 General

Prohibitory!

i 1.3

Note! ... indicates useful tips and recommendations, as well as information for efficient and trouble-free operation.

Limitation of liability All information and instructions in this operating manual have been provided under due consideration of applicable guidelines, the current state of technology, as well as our many years of experience. The manufacturer assumes no liability for damage due to: • • • • • •

Failure to comply with the instructions in the operating manual Non-intended use Deployment of untrained personnel Unauthorized conversions Technical changes Use of non-approved spare parts

The actual delivery condition can vary from the explanations and graphic representations provided in this manual in the case of special versions, if supplemental order options are desired, or on the basis of the latest technical changes. The agreed obligations in the delivery contract, the general terms and conditions, as well as delivery conditions of the manufacturer, and the statutory regulations valid at the time the contract was concluded, apply. Technical prerequisites VULKAN requires, • •

•

that consultation with VULKAN’s technical experts occur before selection of the product. that the purchased VULKAN product only be used and operated in accordance with the “intended use” in the application area prescribed by VULKAN. that the technical information (valid at the time the contract is signed) in the Technical Data Brochures is taken into account during the assembly, disassembly, fault rectification and maintenance tasks.

6/56


1 General

i

Note! The respective version status of the Technical Data Brochure is specified inside the brochure as shown in the example below: 07/2013 The owner must ensure that the points cited above are complied with. If consultation does not occur, and the coupling is configured by the owner at the owner’s own responsibility, the owner also bears the responsibility for selecting the correct Technical Data Brochure appropriate for the product in the VULKAN Download Portal: http://www.vulkan.com/en-us/couplings/downloads/ Moreover, it must be ensured that the version of the assembly manual corresponds to the current status at the time the contract is signed.

i

Note! The respective version status of the assembly manual is specified at the beginning of the manual as shown in the example below: 0000001064 001 7.4.14

1.4

Spare parts WARNING! Incorrect or defective spare parts can cause damage, malfunction, or total failure; they can also impair safety. Therefore: •

Only use manufacturer's original spare parts.

Spare parts Order via authorized dealers or directly from VULKAN customer service. See section "Customer service" for the contact address. Specify the following information when ordering spare parts: • • •

1.5

Order number or consignment number Drawing number Parts list number

Warranty terms The warranty terms are included in the manufacturer's terms and conditions.

1.6

Customer service Our customer service organization is available for technical information. 7/56


1 General The responsible contact is always available at the following contact address: Customer service: VULKAN Kupplungs- und Getriebebau B. Hackforth GmbH & Co. KG Heerstrasse 66 44653 Herne Germany Tel.:+49 (0) 2325 / 922-0 Fax:+49 (0) 2325 / 711 10 Mobile: +49 (0) 178 / 8 922 179 In addition our employees are always interested in new information and experiences associated with the application that could be valuable for the improvement of our products.

8/56


2 Safety

2

Safety

2.1

Responsibility of the owner This section provides an overview of all the important safety aspects for optimal protection of personnel, as well as for safe and trouble-free operation. Significant hazards can occur if the handling instructions and safety instructions in this manual are not complied with. The VULKARDAN L coupling is used in commercial operation. Consequently the owner of the VULKARDAN L coupling is subject to legal industrial safety obligations. In addition to the industrial safety instructions in this operating manual, generally valid safety and accident protection guidelines, and environmental protection guidelines must be heeded and complied with for the area of implementation of the VULKARDAN L coupling. The following particularly applies in this regard: •

•

• •

• •

The owner must inform himself of applicable occupational health and safety regulations, and in a hazard analysis identify other hazards that may exist at the installation site of the coupling due to the special work conditions. The owner must convert this information relative to hazards into operating instructions for operation of the coupling. The owner must ensure during the entire implementation period of the coupling that the operating instructions created by the owner correspond to the current state of legislation, and if necessary the owner must adapt these operating instructions. The owner must clearly regulate and specify responsibilities for installation, operation, maintenance, and cleaning. The owner must ensure that all employees who handle the coupling have read and understood the operating manual. In addition, customer must train personnel and inform personnel of the hazards at regular intervals. The owner must attach a distance protection fixture in the form of a coupling protector before commencing operation of the system. The owner must provide the required protective equipment for personnel.

Moreover the owner is responsible for ensuring that the coupling is always in technically faultless condition; consequently the following applies: • •

The owner must ensure that the maintenance intervals described in this operating manual are complied with. The owner must have all safety devices inspected regularly for function and for completeness.

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2 Safety

2.2

Intended use The VULKAN- VULKARDAN L coupling is a highly-elastic fully flexible rubber coupling for use as an axial and radial guided intermediate coupling for cardan shaft drives. It has been especially developed for a particular application case and can only be used for a different application after consultation with the manufacturer.

2.3

Special dangers Residual risks that have been determined based on a risk assessment are cited below. Follow the safety instructions listed here and the warning instructions in the other sections of this manual to reduce health hazards and to avoid dangerous situations.



•


10/56


2 Safety

WARNING! Life-threatening danger and danger of material damage due to incomplete or incorrect assembly! If there is a mechanical failure of components and incomplete or incorrect assembly, coupling parts can be thrown out at high speed due to rotation. This poses a life-threatening hazard and danger of material damage. Therefore: •


•

Only operate the coupling within the protective fixture described in the "Assembly" section. This protective fixture must be installed by the owner.

•

After working on the coupling, ensure that all bolt connections are firmly tightened in accordance with the specified tightening torques (see drawing).

11/56


3 Technical data

3

Technical data

3.1

Consignment number The consignment number The consignment number is on the outer diameter of the driven-side hub. It has been stamped on.

Fig. 3-1

12/56



4


4.1

Mode of operation The VULKARDAN L coupling is a highly elastic, rubber-ring coupling. All connecting elements of the coupling are positioned in such a way that there is no backlash. Play-free torque transmission and the large rubber cross section guarantee good structure-borne sound absorption. Inner parts and outer parts of the coupling are propped against each other. This axial and radial slide-bearing support absorbs the weight of the cardan shaft and generated forces. The short, compact design results in low crank shaft load even if there are large diffraction angles of the cardan shaft.

4.2

Structure of the coupling Connecting flange The connecting flange connects the drive-side cardan shaft with the elastic part and the bearing ring. It sits in the centring element of the bearing ring and is held together with the elastic part with a threaded joint.

Fig. 4-1

Elastic element The basic element of the coupling is the elastic element, also referred to as the elastic part. The elastic element is used to tune the torsional oscillation. The elastic element cannot compensate axial, radial and angular displacement.

13/56



Fig. 4-2

Flange with bearing ring The flange (1) connects the elastic part to the disk flange. The flange (1) is guided axially and radially on the bearing ring (3) via a slide bearing support (2). The slide bearing support (2) accommodates the weight of the cardan shaft and the forces generated by it. Additional damping is provided through the slide bearing support (2).

Fig. 4-3

Disk flange The disk flange connects the flange with the drive-side machine. It sits on the centring element of the flange and is held in place with a threaded joint.

14/56



Fig. 4-4

15/56



5


5.1

Safety instructions for transport CAUTION! Improper transport can cause damage! Significant damage can occur if the device is transported improperly. Therefore:

5.2

•

Proceed with caution when unloading packages at delivery, as well as for inner-company transport, and comply with the symbols and instructions on the packaging.

•


•


•


Symbols on the packaging Attachment point Only place sling gear (attachment chain, lifting strap) at the points marked with this symbol.

Fig. 5-1

Weight, attached load Indicates the weight of packages. Handle the marked package in accordance with its weight.

16/56



Fig. 5-2

5.3

Delivery status The coupling is delivered in partially-assembled status for easier assembly. After consultation with VULKAN the coupling components can also be sent to different locations, e.g. for pre-mounting of hubs. The precise See the drawing in the Appendix for the delivery status.

5.4

Packaging About the packaging Individual packed goods are packaged according to the expected transport conditions. Environmentally-friendly materials have been used exclusively for the packaging. Packaging should protect the specific components from transport damage, corrosion, and other damage until assembly. Consequently do not destroy the packaging and only remove it just before assembly.

Fig. 5-3

17/56



Fig. 5-4

Handling packaging materials Dispose of packaging materials in accordance with the respectively valid statutory regulations and local guidelines.

5.5

Preservation

5.5.1

General instructions CAUTION! Corrosion preventatives are harmful! Toxic hazard if fumes or aerosols of the corrosion preventative are inhaled! Repeated or longer contact can cause skin irritation or skin diseases. Therefore: •


•

Only remove the corrosion preventative in well-ventilated areas.

•

Avoid contact with skin and eyes: When working, wear chemicalresistant protective gloves and protective goggles with side protection. After work wash thoroughly and use skin-care cream.

•

If inhaled get the person affected to fresh air immediately. If there is skin or eye contact rinse immediately and thoroughly with water.

•

In case of accidents immediately consult a doctor!

•

The individual manufacturers' safety data sheets must be strictly complied with!

18/56



Table Metacorin/VCI/Rolimeco Overview of corrosion preventatives used by VULKAN

Standard corrosion protection Membrane assemblies up to 6 months (stored outdoors under a roof)

Additional corrosion protection Steel parts, cast parts and vulcanized steel and cast parts > 12 months (stored indoors in a dry room)



Parts in VCI foil or aluminum foil; inside with VCI foam dispenser, if necessary




Parts in VCI foil; inside with VCI foam dispenser, if necessary




Parts in VCI foil




Not necessary!

Standard corrosion protection Steel and cast parts up to 6 months (stored outdoors under a roof)

Standard corrosion protection Vulcanized steel and cast parts up to 4 months (stored outdoors under a roof)

See freight overseas, tropical and sub-tropical regions


Intercontinental shipping points

within Europe Short hauls, domestic, bordering states per carrier

Tbl. 5-1

5.5.3

Preservation with Metacorin

i

Note! Material damage due to improper removal of the corrosion preventative! Mechanical removal of the corrosion preventative (e.g. with abrasive agents or tools) can damage surfaces and fit. Therefore: Use a suitable solvent or alkaline cleaning agents.

19/56



i

Note! Material damage due to solvent! Do not bring the rubber elements into contact with solvents! Preservation of steel and cast parts with Metacorin 835 and Metacorin 850 The following types of steel parts are generally protected against corrosion with the corrosion preventative METACORIN 835/850: For steel and cast parts on surfaces and stamped images treated to finish dimension Metacorin 835 offers sufficient protection in case of: • •


The layer thickness of the preservation agent is 4 - 6 µm. Metacorin 850 offers sufficient protection in case of: • •


The layer thickness of the preservation agent is 5 - 8 µm. Cleaning To clean off the Metacorin 835 corrosion preventative film we recommend spraying or immersing in an aqueous-alkaline solution. The cleaning process should generally be supplemented by mechanical cleaning.

i i

Note! Always use lint-free cloths for cleaning.

Note! The connection surfaces and bores are preserved with corrosion preventative or the coupling is packed in VCI foil. Before installing the coupling, use cleaner to clean surfaces that have been treated with corrosion preventative.

20/56



Preservation of VCI

i

Note! Do not treat elastomers and rubber parts with the corrosion preventative. Preservation of elastomer will void the warranty. Preservation with VCI 126 foil

i

Note! The VCI foil used by VULKAN is PE foil with the VCI additive as vapourphase inhibitors. The inhibitors emerge from the foil in the form of vapour, saturate the enclosed air space and adhere to the bare metal surfaces as invisible, monocular films. They can also reach hard-to-access areas. When used as specified, they provide protection of 2-5 years with an airtight seal. Do not allow the VCI foil to become damaged! If the VCI foil is not replaced immediately after being damaged, VULKAN will assume no liability for any adverse effects on the coupling as a result of corrosion!

Fig. 5-5

5.6

Transport Hub Horizontal transport Screw two eye bolts (A) offset by 180° into the tapped bores of the hub until the collar rests on the hub. 21/56


5 Transport, packaging, and storage Use a shackle or self-closing hook to attach the hub to the eye bolts and connect it with the lifting gear.

Fig. 5-6

Vertical transport Use a shackle to attach the hub to the marked bore (see arrow) and connect with the lifting gear.

Fig. 5-7

Attach the disk flange to the marked bore (arrow) by means of a textile load sling and connect with the hoist. Use suitable load slings as specified in DIN EN 1492.

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Fig. 5-8

Attach the elastic element at the marked position (arrow) by means of a textile load sling and connect with the hoist. Use suitable load slings as specified in DIN EN 1492.

Fig. 5-9

5.7

Storage Storage of packages

23/56


5 Transport, packaging, and storage Only store packages under the following conditions: • • • • • • • •

• •

i i

Do not store outdoors. Store in a dry and dust-free location. Do not expose to aggressive media. Protect from direct sunlight. Avoid mechanical shocks. Storage temperature: 15 to 25°C. Relative humidity: Max. 60%. For longer periods of storage (> 3 months) regularly check the general status of all parts and the status of the packaging. Touch up or reapply anti-corrosion agents as needed. If stored for longer than 3 years, a repetition of the static test of the elastic elements is required. For storage longer than 5 years the technical data, such as dynamic torsion spring stiffness and static angle of rotation characteristic of the elastic elements, must be checked.

Note! Under certain circumstances storage instructions are on the packages that extend beyond the requirements cited here. Comply with these instructions accordingly. Note! Material damage if stored incorrectly! Incorrect storage of the elastic elements can cause irreversible deformation of the elastomer. The consequence is uncontrolled torsional oscillation that can destroy the elastic element. Therefore: Store the elastic element horizontally. Do not stress the elastic element axially, e.g. by stacking additional weights. Do not set up the elastic element diagonally or on one side. Storing the elastic elements

Fig. 5-10

24/56



Fig. 5-11

Fig. 5-12

Fig. 5-13

25/56


6 Assembly

6

Assembly

6.1

Safety assembly Safety personnel • •

Only trained, specialized personnel should perform assembly work. If the customer desires assembly can also be executed by Vulkan employees.

WARNING! There is an injury hazard if the device is not installed and commissioned properly! Improper assembly and commissioning can cause serious injury or material damage. Therefore: •


•


•


•


•


DANGER! Life-threatening danger due to commissioning and restarting without authorization! When installing there is danger of the energy supply being switched on without authorization. This poses a life-threatening danger for persons in the danger zone. Therefore: •


•


26/56


6 Assembly



•


Always make sure to perform the assembly steps in the sequence described here.

i

Note! Material damage due to change in the direction of rotation for used elastic elements! Elastic elements are subject to premature material wear if the original direction of rotation is changed and the parts are reused. Therefore: When reusing elastic elements install them in the original direction of rotation. Pay attention to the markings on the elastic element and the connecting components.

i

Note! Material damage due to improper removal of the corrosion preventative! Mechanical removal of the corrosion preventative (e.g. with abrasive agents or tools) can damage surfaces and fit. Therefore: Use a suitable solvent or alkaline cleaning agents.

i

Note!

All connection elements and threaded bores must be lubricated with motor oil before such elements are inserted.

27/56


6 Assembly 6.2

Preparing the coupling for installation

i

Note! Grease the bearing bush and thrust washer before they are inserted. Use only greases without solid lubricants. 1. Unscrew the fastening elements (9) and (12). 2. Lift the disk flange (10) and place it in a secure location where there is adequate space.

Fig. 6-1

6.3

Mounting the disc flange 1. Slide the disk flange (10) onto the centring element of the drive-side flange (A) and bolt it with the fastening elements (B), hand-tight.

Fig. 6-2

i

Note! The owner must dimension the fastening elements (B) and their necessary tightening torque.

28/56


6 Assembly 2. Use a torque wrench to tighten the fastening element taking the prescribed tightening torque into account.

6.4

Mounting the coupling on the drive side Mounting the coupling on the drive side: 1. Attach the coupling at the marked point (arrow) via a textile load sling and connect with the hoist. Use suitable load slings as specified in DIN EN 1492. 2. Lift the coupling into the plant.

Fig. 6-3

3. Bolt the flange (1) and disk flange (10) together using the fastening elements (9) and (12) and tighten hand tight.Slacken the hoist and take off the load sling. 4. Use a torque wrench to tighten the fastening elements to the specified tightening torque (see drawing in the Appendix for tightening torque).

Fig. 6-4

29/56


6 Assembly 6.5

Mounting the coupling on the driven side 1. Position the driven-side machine with pre-assembled cardan shaft in front of the coupling. 2. Slide the cardan shaft (A) onto the centring element of the connecting flange (3) and screw on with the fastening elements (B), hand-tight.

Fig. 6-5

i

Note! The owner must dimension the fastening elements (B) and their necessary tightening torque. 3. Use a torque wrench to tighten the fastening elements, taking the prescribed tightening torque into account.

6.6

Alignment Alignment It is not necessary to align VULKARDAN L couplings, as these are cardan shaft intermediate couplings. In this case the plant is aligned via the cardan shaft. See the separate manual provided by the manufacturer of the cardan shaft for additional requirements.

6.7

Concluding tasks and final inspection Concluding tasks and final inspection 1. Tighten all threaded connections with a torque wrench in compliance with the specified torque (see Tightening torques). 2. Installation of the coupling is concluded. Execute a concluding alignment check (--> Chapter “Alignment”). 3. Ensure that on the owner side a distance-protection fixture in the form of a coupling guard has been attached before the unit is placed in service (--> chapter “Responsibility of the owner”). ª This concludes assembly of the coupling.

30/56


7 Faults

7

Faults

7.1

Safety faults Possible fault causes and the tasks to correct these faults are described in the following section. If faults occur more frequently, the maintenance intervals must be shortened to correspond to actual system load. Contact the manufacturer if there are faults that cannot be corrected by following the instructions below (see "Customer service"). Personnel •

The maintenance and troubleshooting tasks described here should only be performed by experts with special training, or exclusively by the manufacturer. Special reference will be made to the requirement for personal protective equipment or the requirement for experts with special training in the description of the specific fault.


i 7.2

•


•


Note! The fault table provided below lists personnel who are authorized to correct the fault.

Fault table

Fault

Possible cause

Fault correction

Corrected by

Cracks in the elastomer


Perform maintenance and eliminate crack formation

Specialist

End of service life has been exceeded

Replace the elastic element

Specialist

31/56


7 Faults

Fault

Unusual operating noise

Increased bearing forces

Destruction of an elastic element

Possible cause

Fault correction

Corrected by

Inadequate coupling ventilation

Improve the ventilation and eliminate crack formation

Specialist

Faulty alignment

Correct alignment and eliminate crack formation

Specialist

Overload

Only operate the coupling in the prescribed load range and eliminate crack formation

Specialist

Inadequate surface protection

Replace the surface protection and eliminate crack formation

Specialist

Faulty alignment

Alignment check

Specialist

Faulty installation of elastic element or membrane assembly

Check the radial runout and eliminate mounting error

Specialist



Specialist

Faulty alignment

Alignment check

Specialist

Faulty installation of elastic element or membrane assembly

Check the radial runout and eliminate mounting error

Specialist



Specialist



Specialist

End of service life has been exceeded


Specialist

Blocking in the system

Resolve blocking and replace elastic element

Specialist

Propeller contact


Specialist

Short circuit in generator


Specialist

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7 Faults

Fault

Possible cause

Fault correction

Corrected by

Out-of-phase synchronization in generator


Specialist Tbl. 7-1

7.3

Fault correction tasks Venting the coupling • •

•

Execution only by a specialist assigned by the owner. To prevent unnecessary and impermissible warming of the elastic elements, a suitable coupling protection element (e.g. perforated plate) with appropriate ventilation cross-sections must be selected. Ensure that applicable standards for separating spacing protection fixtures are complied with.

Replacing the elastic part •

Execution only by a specialist.

1. Dismantle the elastic part ( section "Dismantling the elastic part"). 2. Mount new elastic part (section "Mounting the elastic part"). 3. Perform final inspection (see "Concluding tasks and final inspection"). 1. Detach the coupling on the driven side (see section "Dismounting the driven-side coupling”). 2. Detach the coupling on the drive side (see section "Dismounting the drive-side coupling”). 3. Place the coupling on the bearing ring (2). 4. Unscrew fastening elements (8) and (9). 5. Take off the flexible section (7) upward and place it in a secure location where there is adequate space.

33/56


7 Faults

7

8

9

2

Fig. 7-1

6. Ensure that the connecting flange (3) sits in the centring element of the bearing ring (2).

3

2

Fig. 7-2

7. Press the new flexible section (7) into the centring device of the connecting flange (3). 8. Screw on the fastening elements (8) and (9) hand-tight. 9. Use a torque wrench to tighten the fastening elements to the specified tightening torque (see drawing in the Appendix for tightening torque). 10. Mount the coupling on the drive side (see section "Mounting the driveside coupling"). 11. Mount the coupling on the driven side (see section "Mounting the driven-side coupling"). 12. Perform final inspection (see section "Concluding tasks and final inspection").

34/56


7 Faults

7

3

8

9

Fig. 7-3

1. Detach the coupling on the driven side (see section "Dismounting the driven-side coupling”). 2. Detach the coupling on the drive side (see section "Dismounting the drive-side coupling”). 3. Place the coupling on the connecting flange (8). 4. Unscrew the fastening elements (9). 5. Lift the flange (2), thrust washer (3), bearing bush (4) and casing (1) off of the flexible section (5) and place them in a secure location where there is adequate space.

2

1

3

4

5

9

8

Fig. 7-4

6. Take off the flexible section (5) and place it in a secure location where there is adequate space. 7. Press the new flexible section (5) into the centring device of the connecting flange (8).

35/56


7 Faults

5

8

Fig. 7-5

8. Lightly grease the bearing bush on all sides (4) and slide it on the flexible section (5).

i

Note! Use only grease without solid lubricants. 9. Lightly grease the thrust washer on all sides (3) and place it on the flexible section (5).

3

4

5

Fig. 7-6

10. Insert the casing (1) into the centring element of the flexible section (5).

36/56


7 Faults

1

5

Fig. 7-7

11. Slide the flange (2) onto the bearing bush (4). Ensure that the flange (2) sits in the centring element of the casing (1). 12. Screw on the fastening elements (9), hand tight. 13. Use a torque wrench to tighten the fastening elements to the specified tightening torque (see drawing in the Appendix for tightening torque). 14. Mount the coupling on the drive side (see section "Mounting the driveside coupling"). 15. Mount the coupling on the driven side (see section "Mounting the driven-side coupling"). 16. Perform final inspection (see section "Concluding tasks and final inspection").

2

4

9

1

Fig. 7-8

Replacing the bearing bush and thrust washer Execution only by a specialist. If the wear limits of the bearing bush and the thrust washer have been exceeded, they must be replaced ( section “Maintenance tasks, checking the bearing bush and thrust bearing").

37/56


7 Faults 7.4

Start-up after a corrected fault After correcting the fault and before switching on, perform the following steps: 1. Check all previously loosened threaded unions for firm seat. 2. Ensure that all previously removed protective devices and covers have been properly installed. 3. Ensure that all tools, materials, and other equipment have/has been removed from the work area. 4. Clean the work area and remove any substances that may have escaped, such as liquids, processing material, or similar items. 5. Ensure that all system safety devices are again functioning properly. 6. Owner-installed emergency stop devices, if present, must be reset. 7. Ensure that no one is in the danger zone.

38/56


8 Maintenance

8

Maintenance

8.1

Safety maintenance Personnel •

The maintenance and troubleshooting tasks described here should only be performed by experts with special training, or exclusively by the manufacturer. Special reference will be made to the requirement for personal protective equipment or the requirement for experts with special training in the description of the specific fault.


8.2

•


•


Maintenance schedule Maintenance tasks are described in the sections below that are required for optimal and trouble-free operation. If increased wear is detected during regular inspections, then reduce the required maintenance intervals according to the actual indications of wear. Contact the manufacturer if you have questions concerning maintenance tasks and intervals (see service address). Interval

Maintenance task

To be performed by:

yearly

Visual inspection for surface cracks

Specialist

after 1000 operating hours

Inspection of the bearing bush and thrust bearing

Specialist

If there is damage or malfunction

Dismantle the flexible element (after a defect has been determined)

Specialist

Tbl. 8-1

39/56


8 Maintenance Damage or malfunction due to: • • • •

8.3

Short circuit in generator operation Faulty synchronization in generator operation Regulator oscillation Emergency shut-off

Maintenance tasks Checking bearing bush and thrust washer Execution only by a specialist. Required tools: • •

Dial gauge with holder Calliper gauge

Checking the bearing bush 1. Detach the coupling on the driven side (see section "Dismounting the driven-side coupling”). 2. Fasten the dial gauge on the flange (1) and place the measuring prod of the dial gauge on the marked point (arrow) on the connecting flange (3). 1

3

Fig. 8-1

3. Push the connecting flange (3) in the direction of the dial gauge and zero-in the dial gauge.

40/56


8 Maintenance

3

Fig. 8-2

4. Push the connecting flange (3) in the opposite direction and read the bearing play of the bearing bush in the diameter, from the dial gauge. 5. Take off the dial gauge and repeat steps 3 to 5 three times, each time offset by 120°. 6. If the bearing play is < 1.0, you can start with the installation (see chapter “Mounting the coupling on the driven side”). If the bearing play > = 1.0 mm, continue to the next section, “Replacing the bearing bush and checking the thrust washer”.

3

Fig. 8-3

Replacing the bearing bush and checking the thrust washer 1. Detach the coupling on the driven side (see section "Dismounting the driven-side coupling”). 2. Place the coupling on the bearing ring (2). 3. Unscrew fastening elements (8) and (9). 4. Take off the flexible section (7) upward and place it in a secure location where there is adequate space.

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8 Maintenance

8

7

9

2

Fig. 8-4

5. Take off the connecting flange (3) and flange (1) and place them in a secure location where there is adequate space.

1

3

Fig. 8-5

6. Take the thrust washer (4) and slotted bearing bush (5) off of the bearing ring (2).

5

4

2

Fig. 8-6

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8 Maintenance 7. Measure the thickness S of the thrust washer (4) via the calliper gauge.

4

8. Compare the value S with the following table. Size

New status (mm)

Wear limit (mm)

L 4510

6,0

4,5 Tbl. 8-2

9. If the wear limit is underranged, replace the thrust washer. 10. Lightly grease the bearing bush on all sides (5) and slide it on the bearing ring (2).

i

Note! Use only grease without solid lubricants. 11. Lightly grease the thrust washer on all sides (4) and place it on the bearing ring (2).

5

4

2

Fig. 8-7

12. Fit the connecting flange (3) and flange (1) on the bearing ring (2).

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8 Maintenance

1

3

2

Fig. 8-8

13. Place the elastic section (7) on the centring element of hub (3) and screw on the fastening elements (8) and (9) hand tight. 14. Use a torque wrench to tighten the fastening elements to the specified tightening torque (see drawing in the Appendix for tightening torque). 15. Mount the coupling on the drive side (see chapter “Mounting the coupling on the drive side”). 16. Mount the coupling on the driven side (see chapter “Mounting the coupling on the driven side”).

7

3

8

9

Fig. 8-9

Check surface cracks Execution only by a specialist. Required special tools: • •

Calliper gauge Depth gauge

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8 Maintenance 1. Remove the coupling protection installed by the owner. 2. To determine the depth of the crack in the interior diameter, the flexible element must be removed (see “Replacing the flexible section"). 3. Use the calliper gauge and depth gauge to measure the crack depth "X" on the inner and outer diameter of the flexible element. 4. Compare the measured value with the maximum permissible values in the table below. 5. If the maximum permissible crack depths are exceeded then the flexible element must be replaced (see "Replacing the flexible element").

X X Fig. 8-10

Permissible crack depths Size

Depth X (mm)

Depth Y (mm)

L 4510

1,9

3,2 Tbl. 8-3

Inspecting for irreversible deformations Execution only by a specialist. Required special tools: • •

Calliper gauge Measuring angle

1. Remove the coupling protection installed by the owner. 2. Turn the coupling until the lip is visible and easily accessible.

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8 Maintenance

Fig. 8-11

3. Measure the irreversible deformation "S" on the lip.

S

Fig. 8-12

4. Compare the measured value with the maximum permissible values in the table below. 5. If the maximum permissible irreversible deformation is exceeded then the elastic element must be replaced (see "Dismantling the flexible section"). Permissible permanent deformation Size

S (mm)

L 4510

35 Tbl. 8-4

8.4

Tightening torques The tightening torques for all fastening elements of the coupling are specified on the drawing in the Appendix and must be complied with.

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8 Maintenance 8.5

Measures after successful maintenance Execute the following steps after concluding maintenance tasks and before switching the system on: 1. Check all previously loosened threaded unions for firm seat. 2. Ensure that all previously removed protective devices and covers have been properly installed. 3. Ensure that all tools, materials, and other equipment have/has been removed from the work area. 4. Clean the work area and remove any substances that may have escaped, such as liquids, processing material, or similar items. 5. Ensure that all system safety devices are again functioning properly. 6. Owner-installed emergency stop devices, if present, must be reset. 7. Ensure that no one is in the danger zone.

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9 Dismantling

9

Dismantling

9.1

Safety dismantling • •

Only trained, specialized personnel should perform dismantling work. If the customer so desires the dismantling process can also be executed by Vulkan employees.

DANGER! Life-threatening danger due to commissioning and restarting without authorization! When installing there is danger of the energy supply being switched on without authorization. This poses a life-threatening danger for persons in the danger zone. Therefore: •


•


WARNING! Life-threatening hazard - High elastic forces! The rubber elements can store extremely high levels of energy, when they are deflected. Sudden loosening of obstructions can cause high energy movements of coupling parts, and in the process cause lifethreatening injury. Therefore:

9.2

•


•


Dismantling sequence Carry out the dismantling procedure in the sequence described here.

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9 Dismantling

CAUTION! Material damage due to a change in the direction of rotation when reusing elastic parts! Elastic parts are subject to premature material wear if the original direction of rotation is changed and the parts are reused. Therefore: •

If reuse is planned, check the markings on all coupling parts, if necessary affix new, easy-to-understand markings.

Prohibitory! Do not disassemble the membrane package of the membrane assembly into single parts!

9.2.1

Dismounting the coupling on the driven side 1. Unscrew the fastening elements (B). 2. Pull the cardan shaft (A) from the centring element of the connecting flange (3).

Fig. 9-1

9.2.2

Dismantling the coupling on the drive side 1. Attach the coupling at the marked point (see arrow) via a textile load sling and connect with the hoist. Use suitable load slings as specified in DIN EN 1492. 2. Raise slightly until slightly tensioned. 3. Unscrew the fastening elements (9), and (12) from the flange (1) and the disk flange (10). 4. Pull the coupling out of the centring element of the disk flange (10). 5. Lift the coupling out of the plant and put it down at a safe spot where there is sufficient space. 6. Slacken the hoist and take off the load sling. 49/56


9 Dismantling

Fig. 9-2

9.2.3

Dismounting the plate flange 1. Attach the disk flange (10) to the marked bore (arrow) by means of a shackle and connect with the hoist. Use suitable shackles in accordance with DIN EN 13889. 2. Raise slightly until slightly tensioned. 3. Unscrew the fastening elements (B) from the disk flange and the drive-side flange (A). 4. Lift the disk flange (10) out of the plant and put it down at a safe spot where there is sufficient space. 5. Slacken the lifting gear and unscrew the shackles.

Fig. 9-3

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9 Dismantling 9.3

Disposal If a return or disposal agreement has not been concluded, then recycle dismantled components: if a return or disposal agreement has not been concluded, then recycle dismantled components: • • •

Dispose of rubber mixtures in accordance with governmental guidelines. Sort and dispose of the remaining components in accordance with material condition Remove fuels and auxiliary materials, as well as residual processing materials and dispose of these items in an environmentally responsible manner.

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11 Index

11

Index

A

Mounting the disk flange

Alignment 30 Assembly drawing 52 Assembly Manual 5 Assembly parts list 53 Attachment 16

O Operating manual

9

P Permissible crack depths 45 Permissible permanent deformation Personnel;troubleshooting 31, 39 Preservation 19, 20, 21

B Bearing play

28

41

46

C Checking the bearing bush 40 Commissioning 26 Concluding tasks and final inspection Connecting flange 13 Consignment number 12 Contact 8 Customer service 8

R Replacing the bearing bush and checking the thrust washer 41 Replacing the bearing bush and thrust washer 37, 40

30

S Safety assembly 26, 48 Safety instructions 5 Safety personnel 26 Spare parts 7 Startup after troubleshooting 38 Storage 24 Storage of packages 23 Structure and function 13 Surface cracks 44 Symbols on the packaging 16

D Dangers 10 Delivery status 17 Disk flange 14 Dismantling sequence 48 Disposal 51 Disposal of packaging 18

E Elastic element 13 Elastic forces 10, 27, 48 Explanation of symbols 5

T Technical prerequisites 6 Tightening torques 46 Transport 16 Troubleshooting 33

F Faults 31 Flange with bearing ring

14

W I Intended use 10 Irreversible deformations

Warranty 7 Wear limit 43 45

L Liability 6 Limitation of liability

6

M Maintenance schedule 39 Maintenance schedule table 40 Measures after successful maintenance

47 55/56


11 Index

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900 Power Transmission

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