WESTCAR ROTOMEC ALFA Original Instructions Manual Download Page 3

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o w e r

r a n s m i s s i o n

nstallation

and

maintenance

manual

ROTOMEC

INDEX

PART

REFERENCE DOCUMENTS

2 - 7

0.0

DECLARATION OF INCORPORATION (ENCLOSED)

0.1

ROTOMEC COUPLING TECHNICAL DATA SHEET

0.2

INDEX

0.3

COMPONENT DEFINITIONS

0.4

MANUAL LAYOUT AND SYMBOLS

5 - 7

PART

INTRODUCTION INFORMATION

8 - 16

1.1

WESTCAR INSTRUCTION LETTER ON DELIVERY

1.2

HYDROMECHANIC COUPLING IDENTIFICATION

1.3

MARKING OF HYDROMECHANIC COUPLING ACCORDING TO ATEX STANDARD

1.4

WARRANTY

1.5

GENERAL INFORMATION ON DELIVERY

1.6

HYDROMECHANIC COUPLING DESCRIPTION

1.7

OPERATING PRINCIPLE

1.8

INTENDED USE AND SAFETY DEVICES

13 - 14

1.9

IMPROPER AND FORBIDDEN USE OF STANDARD AND ATEX COUPLINGS

1.10

REQUIREMENTS FOR STANDARD and/or ATEX INSTALLATION

PART

WARNINGS AND PRESCRIPTIONS

17 - 23

2.1

GENERAL SAFETY RULES

17 - 20

2.2

SAFETY RULES FOR POTENTIALLY EXPLOSIVE ATMOSPHERES

2.3

SAFETY DEVICES AND WARNING LABELS

2.4

SAFETY INSPECTIONS

PART

TRANSPORT AND INSTALLATION

24 - 31

3.1

TRANSPORT OF COUPLING WITH PACKAGE

3.2

HANDLING OF COUPLING WITHOUT PACKAGE

3.3

COUPLING STORAGE AND CONSERVATION

26 - 27

3.4

COUPLING PRE-ASSEMBLY

28 - 29

3.5

ASSEMBLY OF PULLEY FOR BETA COUPLINGS

30 - 31

PART

INSTALLATION AND COMMISSIONING

32 - 47

4.1

PRESCRIPTIONS FOR ROTOMEC COUPLING INSTALLATION IN HAZARDOUS ATMOSPHERES

32 - 33

4.2

FITTING OF ROTOMEC COUPLING ON DRIVE SHAFT

34 - 41

4.3

ASSEMBLY AND ALIGNMENT OF ROTOFLEXI FLEXIBLE COUPLING

42 - 43

4.4

ASSEMBLY AND ALIGNMENT OF SERIES AB FLEXIBLE COUPLING

4.5

SCREW TIGHTENING TORQUES FOR COUPLINGS AND ACCESSORIES

4.6

ROTOMEC COUPLING COMMISSIONING - STANDARD and ATEX MANUFACTURE

46 - 47

PART

5 OPERATION, REPLACEMENT AND/OR RESETTING OF OVERHEATING PROTECTION DEVICES

48 - 51

5.1

FUSIBLE PLUG - TF

5.2

EXPANDABLE PLUG - TE

5.3

PLUG WITH THERMOSTAT AND rmp CONTROLLER - T09 con PM

50 - 51

PART

TRANSMISSION OIL FILLING AND CALIBRATION

52 - 68

6.1

TRANSMISSION OIL TECHNICAL CHARACTERISTICS

52 - 53

6.2

TABLES FOR COUPLING FILLING

6.3

FILLING AND CALIBRATION OF HORIZONTALLY MOUNTED COUPLINGS

55 - 59

6.4

FILLING AND CALIBRATION OF VERTICALLY MOUNTED COUPLINGS

60 - 63

6.5

TRANSMISSION OIL REPLACEMENT IN HORIZONTALLY MOUNTED COUPLINGS

64 - 65

6.6

TRANSMISSION OIL REPLACEMENT IN VERTICALLY MOUNTED COUPLINGS

66 - 67

6.7

TABLE FOR RESIDUAL OIL DEPLETION IN VERTICALLY MOUNTED COUPLINGS

PART

ORDINARY MAINTENANCE

69 - 76

7.1

OIL LEAKAGE CHECK

7.2

OIL LEVEL CHECK AND TOP-UP

70 - 71

7.3

EXTERNAL CLEANING OF THE COUPLING

7.4

INSPECTION OF OVERHEATING CONTROL DEVICES

7.5

SERVICE RECORD

74 - 75

7.6

COUPLING OUTER PROFILE AND MAIN ELEMENTS

PART

INCONVENIENCES AND REMEDIES

77 - 78

PART

EXTRAORDINARY MAINTENANCE

79 - 82

9.1

COUPLING DISASSEMBLY FROM MACHINE

9.2

OPENING OF THE COUPLING AND SPARE PARTS REPLACEMENT

80 - 81

9.3

SPARE PARTS

PART

DECOMMISSIONING AND DEMOLITION

10.1

COUPLING DECOMMISSIONING

10.2

FLUID COUPLING DISMANTLING AND DEMOLITION

Summary of Contents for ROTOMEC ALFA

Page 1: ...i o n s WESTCAR s r l Via Monte Rosa 14 20149 MILANO Tel 39 02 76110319 Fax 39 02 76110041 i n f o w e s t c a r i t www westcar it Constant fill HYDRO MECHANIC COUPLINGS ROTOMEC ROTOMEC ROTOMEC ALFA ROTOMEC BETA M2021 ENG ed 2021 04 ...

Page 2: ...__ V _____ Hz _____ Rpm Installed Power __________________ kW Power input __________________________ kW DRIVEN SIDE DATAS Installation Flexible coupling YES NO Drive through pulley ROTOFLEXI type ______ bore Ø _____ Primitive diameter ___________________________ ROTOPIN type ______ bore Ø _____ Grooves section ________ N grooves ___________ ROTOGEAR type ______ bore Ø _____ bore Ø ______________ b...

Page 3: ...OUPLING ON DRIVE SHAFT 34 41 4 3 ASSEMBLY AND ALIGNMENT OF ROTOFLEXI FLEXIBLE COUPLING 42 43 4 4 ASSEMBLY AND ALIGNMENT OF SERIES AB FLEXIBLE COUPLING 44 4 5 SCREW TIGHTENING TORQUES FOR COUPLINGS AND ACCESSORIES 45 4 6 ROTOMEC COUPLING COMMISSIONING STANDARD and ATEX MANUFACTURE 46 47 PART 5 OPERATION REPLACEMENT AND OR RESETTING OF OVERHEATING PROTECTION DEVICES 48 51 5 1 FUSIBLE PLUG TF 48 5 2 ...

Page 4: ...S external part 3 HOLLOW SHAFT and INNER PRIMARY WHEEL internal part 4 OIL PLUG POSITION STANDARD 5 RADIAL PLUG POSITION OPTIONAL 6 FLEXIBLE COUPLING 7 PRIMARY WHEEL 8 ROTATING GASKETS POS DEFINITION 9 CENTRIFUGAL MASSES 10 ROLLERS CENTRIFUGAL COUPLING 11 RADIAL SHELL SEALING 12 HEAD SCREW 13 PULLEY SLEEVE 14 PULLEY 15 RADIAL BEARINGS TYPES OF HYDROMECHANIC COUPLINGS ROTOMEC ALFA in line ROTOMEC B...

Page 5: ...o the soil as possible about 30 cm and put it under a shelter in a dry place then get the fork lift out of the way 3 1 3 Open the upper part and remove the packaging CAUTION DANGER OF ENVIRONMENTAL POLLUTION Do not dump packaging material in the environment but keep it for any future re use or shipping to the manufacturer or dispose of it properly as industrial waste 3 1 4 Remove any stiffening ri...

Page 6: ...significance The hydromechanic coupling bearing this mark has been manufactured according to the ATEX standards in compliance with the ATEX Directive 2014 34 EU In combination with the text they point out the type of residual risk that the task in progress may involve Danger of ignition and or zones with explosive atmosphere General hazard Heated areas danger of burns Moving components Danger of e...

Page 7: ...rough knowledge and understanding of the manufacturer s instruction handbook as well as the required training Special engineering competencies are required to accomplish mechanical installation and assembly When this sign is matched with the explosion protection symbol the technician or operator must have a profound and specific knowledge of the safety rules necessary to work in these environments...

Page 8: ...s and prescriptions shall always be kept available on site for the technicians who are in charge of the installation and final operators The manufacturer is not liable for any modification tampering or any alteration accomplished in violation of what above described and dealt with in this handbook Any modification not duly authorised in written by Westcar may be dangerous to safety people s and an...

Page 9: ...rvice authorized by WESTCAR always point out the data showed on the identification plate Below you can read the content of the fields of the ID plates fixed on the ROTOMEC hydromechanical coupling POS DESCRIPTION POS DESCRIPTION A WESTCAR logo J Product serial number B Manufacturer s identification data K Oil fill data Calibration C Name of the partly completed machine L Weight of the no load hydr...

Page 10: ...racteristics and its anti explosion protection level as well as the limits of its use M2 High protection category for mining industry 2 High protection category for surface industries I Mining II Surface G Gas D Dust Assembly for gas ignition IIB Ethylene IIC Hydrogen acetylene EPL Protection Level Mb Mining Protection valid for ordinary functioning and foreseeable malfunction Gb Db Surface Protec...

Page 11: ...nician s travelling and maintenance expenses as well as the shipping expenses borne for the removal of any defect will be fully charged 5 Reserved Evaluation The defective parts shall be returned to WESTCAR which reserves the right to check them in its own workshops in order to identify the real defects or the external reasons which may have caused the damage If no defect can be found in the produ...

Page 12: ... pump and the other connected to the machine or driven part called turbine The pump and the turbine are not connected to each other and the transmission of motion and the torque in absence of usury through a suitable transmission fluid with which the hydromechanical coupling is filled The mechanical power supplied by the motor or motor part to which the cou pling pump is connected is transformed i...

Page 13: ... the driven machine The full capacity operation of the ROTOMEC coupling occurs in the absence of sliding of the input revolution com pared to the output ones thanks to the combination of the hydromechanic circuit state and the internal centrifugal coupling 1 8 INTENDED USE AND SAFETY DEVICES INTEDED USE The ROTOMEC constant fill hydromechanic couplings have been designed and built to transmit the ...

Page 14: ...ng conditions it is necessary not to exceed the MAXIMUM NUMBER OF START UP PROCEDURES HOUR AND OR THE MAXIMUM NUMBER OF CONSECUTIVE START UP PROCEDURES which shall comply with the results obtained from the formulas reported in the WESTCAR catalogue SAFETY AND TEMPERATURE CONTROL DEVICES The constant fill hydromechanic coupling is configured according to the specific customer s needs and equipped w...

Page 15: ...riorated or are different from what reported on coupling configuration see Technical Data Sheet in case the motor is lacking of an automatic shutdown device which may block it in the event of transmission fluid leakage TF or triggering of maxi mum temperature devices TE or PM when there are no suitable protections and or fluid containment elements for couplings equipped with TF if a suitable venti...

Page 16: ...in potentially explosive atmospheres where methane concentration is lower than 1 correct identification of enviorment I mining II surfaces ind category M2 mining 2 surfaces ind Epl Protection Level Mb mining Gb Db surface industries Gas Group Ignition IIB IIC CAUTION This handbook must be forwarded to the final user of the machine or partly completed machine where the hydromechanic coupling will b...

Page 17: ...gral clamping system using appropriate devices as foreseen by the manufacturer central clamping screw see section 2 3 Any installation of the hydromechanic coupling not integral to the plant or accomplished through devices which are not included in the manufacturer s recommended parts list is not allowed RISK OF UNBALANCE AND OR DYNAMIC FAILURE 2 1 5 The installation room must have suitable air in...

Page 18: ...r more safety devices for overheating control Do not tamper with remove and or disable the installed safety device After triggering it is necessary to restore and or replace the device with an original spare part having identical triggering characteristics and to reset it before restarting the drive end DANGER OF OVERHEATING SEIZURE AND OR FIRE 2 1 13 The installation of the hydromechanic coupling...

Page 19: ... 19 The hydromechanic coupling has been designed for a maximum amount of start up hour see WESTCAR Technical Catalogue Never exceed the maximum amount of start up procedures hour and or never start up for a longer time than allowed by the manufacturer DANGER OF OVERHEATING 2 1 20 The standard hydromechanic coupling is designed for continuous operation uninterrupted rotation for periods not exceedi...

Page 20: ...dampened with neutral detergents Do not use inflammable solvents liquid agents or dry synthetic cloths which may become electrostatically charged FIRE DANGER 2 1 26 Regulation and or maintenance shall be carried out by trained and authorized Technicians Do not tamper and or alter the state of the art technology of the fluid coupling 2 1 27 Worn parts or triggered protections must be replaced by or...

Page 21: ...erent temperature classes T3 T4 T5 and T6 Do not use the coupling in a hazardous environment with unsuitable oil or oil whose temperature class is inadequate or not in compliance with both the coupling manufacture and the environment classification FIRE DANGER 2 2 4 Do not expose the external surfaces of the hydromechanic coupling to hot air streams and or sources or accumulators of electrostatic ...

Page 22: ...luid from the hydromechanic coupling and any drive failure at the driven machine when the maximum temperature of the fitted TF is exceeded E2 EXPANDABLE TRIP PLUG TE EXPANDABLE TRIP PLUG TE It permits to detect the overheating value as set up in the fitted TE through release of the signalling stud by a suitable microswitch which shall be of ET type for standard and ETA type for ATEX manufacture E3...

Page 23: ...e sure that no oil overflow or leakage have occurred If so promptly remove and dry up the coupling before handling it detect the origin of the transmission oil leakage and make the necessary arrangements before going on using the hydromechanic coupling 2 4 8 Check up on integrity of the safety and overheating control devices and the correct positioning of the electric detectors microswitch for TE ...

Page 24: ...e packaging CAUTION DANGER OF ENVIRONMENTAL POLLUTION Do not dump packaging material in the environment but keep it for any future re use or shipping to the manufacturer or dispose of it properly as industrial waste 3 1 4 Remove any stiffening rib plastic film for internal protection and brackets that fix the hydromechanic coupling to the pallet NOTE Should the product be sent to the factory for r...

Page 25: ... position Screw in the threaded pin equipped with hoisting ring in the extrac tion hole of the coupling 3 2 3 Sling the coupling through the hoisting ring with hoist lines of suitable load capacity for the coupling weight see Identification Plate 3 2 4 By slow movements lift the coupling and transfer it to a dry sheltered place and lay it on a wooden plane next to motor and drive end where the cou...

Page 26: ...n 3 3 1a The coupling must be filled with transmission oil before storage if not the shaft sealing must be protected with suitable grease AGIP 33FD SHELL Alvania R3 or equivalent 3 3 1b Clean the external surfaces of the coupling and protect them with suitable protection lubricant type CRC 3 36 or equivalent CAUTION The hydromechanic coupling and any flexible coupling with rubber elements must be ...

Page 27: ...side and re assemble the plug so to ensure the air tight sealing of the coupling The rotating seals must be greased 3 3 3 ALREADY OPERATED COUPLING UNUSED UP TO 6 MONTHS In this case it is necessary that on shutdown the procedures as per point 3 3 2 are observed 3 3 4 AFTER COUPLING INSTALLATION UNUSED OVER 6 MONTH Follow what described in point 3 3 2 and carry out the prescribed operations every ...

Page 28: ...ed with aggressive or corro sive atmosphere marine environment atmospheres with corrosive acids it is appropriate to use specially manufactured hydromechanic couplings i e with anodized surfaces or it is necessary to coat the aluminium shells as follows Degrease the coupling surfaces with a suitable solvent protecting the shaft sealing Spray the external surfaces with a suitable high temperature r...

Page 29: ...n customers request without pulley If the pulley is not supplied with the hydromechanic coupling and it has not been manufactured by WESTCAR before the pulley is mounted it is necessary to verify what follows The centring diameters must be within tolerance shaft h7 for series Z BETA couplings and H7 holes for series J BETA couplings to enable connection with 0 02mm minimum and 0 05mm maximum clear...

Page 30: ...ngs to enable connection with 0 02mm minimum and 0 05mm maximum clearance The pulley contact plane must be perpendicular to the coupling rotation axis Both concentricity and perpendicularity errors must not exceed 0 1mm All cast iron pulleys or the pulleys whose diameter is larger than Ø200mm must have at least G6 3 balance rating To assemble the pulley on the BETA hydromechanic coupling follow th...

Page 31: ...ATING AND BEARING SEIZURE AND DANGER OF OIL LEAKAGE DUE TO INTERNAL OVERPRESSURE AND POSSIBLE STRUCTURAL FAILURE 6 2 TABLES FOR COUPLING FILLING Part 6 tranSMiSSion oil filling and calibration COUPLING K e SCF FILLING ANGLE α AND HEIGHT h IN mm 30 45 60 75 90 SIZE ØA kg liters h mm kg liters h mm kg liters h mm kg liters h mm kg liters h mm 20 230 1 08 1 23 1 1 14 167 0 85 0 97 150 0 75 0 85 137 0...

Page 32: ...the TECHNICAL DATA SHEET 4 1 6 The WESTCAR couplings are always equipped with protection devices such as fusible plugs TF or expandable trip plugs ET coupled with the limit switch ET A Ex Should oil leak due to the fusible plug TF triggering it is required to stop the motor as soon as possible RISK of overheating of bearings and gasket seals 4 1 7 Couplings with fusibe plug TF may be only used if ...

Page 33: ...at set at a temperature of 100 120 C incorporated in the body of the PM plug and i mounted on the hydromechanic coupling The PM cap is coupled to the Ex sensor connected to the T09 control unit located in a safe area with interposition of the ZENER barrier The PM plug works by transmitting without contact a signal to the Ex sensor placed at 2 5mm from the PM cap When the temperature of the couplin...

Page 34: ...ollow shaft of the coupling inner part VERTICAL ASSEMBLY The hydromechanic coupling produced with C manufacture is designed for vertical installation in order to ease both the filling and the oil level calibration see Identification Plate CAUTION It is forbidden to install the hydromechanical coupling with the motor or the drive part connected to the outer shells of the coupling itself Following y...

Page 35: ...in the table 4 2 2 Measure with a suitable micrometric tool the real dimension of the drive shaft or the machine and the hydromechanic coupling CAUTION The bore shaft connection of the hydromechanic coupling must not be a force fit and no flames or heaters must be used DANGER OF SEAL DAMAGING AND OR IMPOSSIBLE DISASSEMBLING OF THE COUPLING 4 2 3 In case of interference in the connection it is nece...

Page 36: ...over 30 kg fully unscrew and remove one of the screws for coupling shell closure and insert a suitable WESTCAR hoisting device available on request 4 2 4c Sling the hydromechanic coupling on the hoisting device with ropes having load capacity suitable for its weight see Identification Plate 4 2 4d Place on the hole of the drive shaft a threaded bar whose length must be suitable for the hydromechan...

Page 37: ...r in case of couplings provided with extraction holes using the SE extraction system to block the shaft 4 2 4g In case the coupling keying turns out to be difficult and subject to strain dis assemble the coupling see chapter 9 1 DISASSEMBLY OF THE COUPLING and follow the procedure from step 4 again more accurately CAUTION Check the surfaces of the shaft the keys and its seat DANGER OF SEIZURE AND ...

Page 38: ...s without key way remove feather key from drive shaft reduction gear 4 2 5b Accurately clean with a neutral detergent all the contact surfaces between shaft sleeve and taper hole 4 2 5c Position the sleeve using a retainer to be removed after tightening the retaining screw on shaft end NOTE The length of the closely fitted shaft must be lower than the taper hole depth and have a threaded bore on t...

Page 39: ...er and screw it on the drive shaft 4 2 5g Tighten the central clamping screw preventing any motion of the machine or motor shaft where it is mounted For tightening respect the torque values as reported in the table COUPLING SIZE TAPER BUSH BC RETAINING SCREW CLASS TORQUE Nm 30 30P 3BC 54 D ø28 3BC 54 D ø38 3BC 54 D ø42 50 M10 M12 M16 8 8 8 8 8 8 50 80 210 40P 4BC 58 D ø38 40 4BC 58 D ø40 42 4BC 58...

Page 40: ...pling with suitable interlocked protections which prevent the personnel from interfering with the coupling moving components and or the live components of the drive end When couplings are installed in an environment with explosive atmosphere ATEX some accident prevention guards prevent any contact with the rotating components and or protect them from any metal object fall or ejection even from out...

Page 41: ... 4 2 8a ALFA COUPLINGS To install the ALFA in line hydromechanic couplings it is necessary to assemble the accessories rubber element hub etc according to the instructions dealt with in section 4 3 FITTING AND ALIGNMENT OF ROTOFLEXI FLEXIBLE COUPLINGS or 4 4 FITTING AND ALIGNMENT OF AB series FLEXIBLE COUPLINGS 4 2 8b BETA COUPLINGS ToinstallBETAhydromechaniccouplingsforbeltdrive itisnecessarytoas...

Page 42: ...coupling 4 3 2 Fit the hydromechanic coupling or reduction gear 4 3 3 Fit the hub of the flexible coupling on the motor shaft 4 3 4 Alligne driving a driven shaft Now the machine and the motor may be secured definitively providing for a space B between the hub and the flange fixing face which must be equal or wider than the thickness of the rubber element as reported in the tables NOTE Coaxiality ...

Page 43: ...pe K LRV K LRU B K FRV K FRU B Rated Torque Nm KB max KA max A2 A1 ß max E max Size Tightening Torque Nm 2 20 24 65 0 5 0 4 1 0 4 M8 25 3 25 30 32 20 30 175 0 5 0 4 1 15 0 4 M10 50 4 40 40M 36 25 30 34 330 0 5 0 4 1 15 0 4 M12 87 5 55 40 40 40M 38 440 0 8 0 4 1 15 0 4 M14 138 6 65 44 55 42 630 0 8 0 6 1 30 0 6 M14 138 7 75 50 65 48 1160 1 0 6 1 30 0 6 M16 212 8 75 56 2000 1 0 6 1 30 0 6 M18 291 RO...

Page 44: ...ith guide pins is uniform see table B1 B2 dimension 4 4 4 Now the driven machine and the motor can be definitively fixed providing for a space equal to the V dimension between the hub and the fixing face rubber sleeve of the flange with guide pins 4 4 5 in the relevant housings providing for a distance equal to the V dimension shown in the table and fix the hub with proper setscrews AXIAL ERROR AN...

Page 45: ... 6 Pos 7 Pos 8 Pos 9 Pos 10 Pos 11 Pos 12 Pos 13 OIL PLUG SCREWS TORQUE Nm 20 M5 M6 M8 M8 M6 M6 M6 1 4 M5 8 8 6 03 25 M6 M6 M8 M8 M8 M6 M6 1 4 M6 8 8 10 38 30 M8 M8 M10 M10 M8 M8 M8 1 4 M8 8 8 25 16 40 40M M8 M8 M12 M12 M10 M10 M8 1 4 M10 8 8 50 53 55 M8 M10 M10 M14 M14 M10 M10 M10 M10 1 2 M12 8 8 87 08 65 M8 M10 M10 M14 M14 M10 M14 M10 M10 1 2 M14 8 8 138 5 75 M10 M12 M12 M18 M18 M16 M18 M12 M12 ...

Page 46: ...SPARKS AND FIRE IGNITION 4 6 2 HYDROMECHANIC COUPLING WITH TE Expandable Trip Plug To complete the installation of the hydromechanic couplings equipped with the overheating control device TE with ET A observe what follows Set an automatic motor shutdown in case of device triggering DANGER OF OVERHEATING Isolate the hydromechanic coupling with suitable interlocked guards which prevent the personnel...

Page 47: ... maximum safety temperature of the coupling and the overheating control devices it is completed with as shown on the ATEX marking on the product CAUTION Do not use oil not suitable for ATEX environment with flash temper ature T max Lower than the safety temperature reported on the ATEX marketing of the hydromechanic coupling 4 6 4d Promptly remove any oil dripping or leakage from the coupling or t...

Page 48: ... the TF as described below Wait for all moving components to stop Cut out power supply to motor or drive end and apply an appropriate safety padlock Wait for the cooling down of the hydromechanic coupling max 40 C before intervening CAUTION Remove any oil dripping or leakage from the coupling or the soil DANGER OF SLIPPERY FLOOR CRASH AND OR FALL Open the guard to access the hydromechanic coupling...

Page 49: ...e the expandable trip plug is installed it is necessary to replace the TE as described below Wait for all moving components to stop Cut out power supply to motor or drive end and apply an appropriate safety padlock Wait for the cooling down of the hydromechanic coupling max 40 C before intervening Open the guard to access the coupling Check the shaft for oil leakage and the condition of the shaft ...

Page 50: ...PM T09 unit in an environment with hazardous atmosphere ATEX requires the installation of Zener barriers for an intrinsically safe electric system see Original Instruction Manual of the PM T09 unit 5 3 2 MAXIMUM TEMPERATURE CONTROL When the maximum temperature of the hydromechanic coupling is exceeded the sensor detects it and the signal emitted generates an alarm condition and automatically cause...

Page 51: ...ate a pre alarm condition for the pre set time If any rotational slow down has been detected under normal operating conditions for longer than the set up pre alarm time an alarm signal is released and the motor or drive member are automatically shut down Remove the causes which have determined the device triggering due to overheating 5 3 5 T09 RESET DUE TO A REDUCTION IN RPM The alarm released bec...

Page 52: ...Basically oil with viscosity degree among 1 9 and 4 angler may be used CAUTION The oil inside the coupling must be fluid enough to transmit the torque In case of low temperature below 0 C the first start up requires a longer time to transmit the torque until standard operating conditions are reached Therecommendedoilsarelistedbelowaccordingtotheirtechnicalcharacteristics and the properties of envi...

Page 53: ...arly suitable for out door applications OIL TRADEMARK ROLOIL ROLOIL ROLOIL OIL TYPE SYNTHEST 46 BIO SYNTHEST HP 32 BIO SYNTHEST HP 46 BIO VISCOSITY ISO VG 45 32 48 CST A 40 C 45 32 48 ENGLER 4 3 3 VISCOSITY INDEX 190 200 190 DENSITY kg dm3 0 915 0 914 0 914 POURPOINT F 45 4 81 4 81 4 C 43 63 63 FLASHPOINT T max F 563 446 473 C 295 230 245 BIODEGRADABILITY 90 80 80 Part 6 Transmission Oil Filling a...

Page 54: ...ll or a too large amount of fluid DANGER OF OVERHEATING AND BEARING SEIZURE AND DANGER OF OIL LEAKAGE DUE TO INTERNAL OVERPRESSURE AND POSSIBLE STRUCTURAL FAILURE 6 2 TABLES FOR COUPLING FILLING Part 6 Transmission Oil Filling and Calibration COUPLING K e SCF FILLING ANGLE α AND HEIGHT h IN mm 30 45 60 75 90 SIZE ØA kg liters h mm kg liters h mm kg liters h mm kg liters h mm kg liters h mm 20 230 ...

Page 55: ...ing horizontally mounted For different filling angles reported on the first line above of hydromechanic coupling size as pointed out on the first column left you may read the correct angular position of the horizontally mounted coupling and the height of the plug with respect to the lowest point of the external diameter of the coupling CAUTION The hydromechanic coupling must be filled in complianc...

Page 56: ...ydromechanic coupling size as pointed out on the first column left you may read the correct angular position of the horizontally mounted coupling and the height of the plug with respect to the lowest point of the external diameter of the coupling CAUTION The hydromechanic coupling must be filled in compliance with the type of expected start up Do not fill the coupling with a too small or a too lar...

Page 57: ...cation of the lubricant oil screw plug with respect to the vertical axis of the hydromechanic coupling horizontally mounted For different filling angles reported on the first line above of hydromechanic coupling size as pointed out on the first column left you may read the correct angular position of the horizontally mounted coupling and the height of the plug with respect to the lowest point of t...

Page 58: ...f the coupling and drain the oil in excess of the calibration quantity Part 6 tranSMiSSion oil filling and calibration ROTOMEC USe and Maintenance handbook 54 ManUale d USo e ManUtenzione ROTOMEC T r a s m i s s i o n i d i P o T e n z a T r a s m i s s i o n i d i P o T e n z a In questa sezione vengono riportate le tabelle con le quantità di riempimento a livello in litri secondo una disposizion...

Page 59: ... Thermal Plug 96 C 120 C 145 C 180 C ____ C T09 Plug with Thermostat and RPM counter 100 C 120 C 145 C 160 C ____ C STANDARD MANUFACTURE ATEX MANUFACTURE Ambient _____________ Max Temp __________ C Ambient ZONE ______________ Max Temp _______ C DRIVE SIDE DATAS Installation Horizontal Vertical Type of engine Diesel Petrol ________________________ Rpm Electric Voltage _____ V _____ Hz _____ Rpm Ins...

Page 60: ...ty padlock C signal the operation under way D wait for the cooling if needed max 40 C 6 4 1a Open the accident prevention guard of the operating area to access the coupling 6 4 1b Remove the plug or the device whatever part may be positioned on the upper part of the oil filling hole of the coupling CAUTION The maximum filling permitted in couplings designed for vertical installation must never exc...

Page 61: ...l start up B lower power consumption on start up C better protection of the power transmission elements in case of overload D higher slip under stable operating conditions CAUTION Before the hydromechanic coupling is filled and or calibrated observe the following steps A stop the motor and wait for the rotation components to stop B cut out power supply and apply a safety padlock C signal the opera...

Page 62: ...s with the filling quantity in litres for the coupling according to a specific angular location of the lubricant oil screw plug with respect to the vertical axis of the hydromechanic coupling horizontally mounted For different filling angles reported on the first line above of hydromechanic coupling size as pointed out on the first column left you may read the correct angular position of the horiz...

Page 63: ...tion standard constant self lubricating SAFETY TEMPERATURE CONTROL DEVICES SUPPLIED TF Fusible Plug 96 C 120 C 145 C 180 C ____ C ETP Expandable Thermal Plug 96 C 120 C 145 C 180 C ____ C T09 Plug with Thermostat and RPM counter 100 C 120 C 145 C 160 C ____ C STANDARD MANUFACTURE ATEX MANUFACTURE Ambient _____________ Max Temp __________ C Ambient ZONE ______________ Max Temp _______ C DRIVE SIDE ...

Page 64: ...sion oil replacement observe the following steps A stop the motor and wait for the rotation components to stop B cut out power supply and apply a safety padlock C signal the operation under way D wait for the cooling if needed max 40 C 6 5 1 Open the accident prevention guard of the operating area to access the coupling 6 5 2 Manually turn the coupling until the plug reaches an accessible upper po...

Page 65: ...GS The first transmission oil change must be carried out after 2000 operating hours and later every 4000 operating hours The use of the coupling in particularly dusty environments also shortens the planned intervals and requires oil replacement every 1000 operating hours The oil must be changed even after a partial start up of the motor so that impurities are suspended in the oil After that please...

Page 66: ... replacement observe the following steps A stop the motor and wait for the rotation components to stop B cut out power supply and apply a safety padlock C signal the operation under way D wait for the cooling if needed max 40 C 6 6 1 Open the accident prevention guard of the operating room to access the coupling 6 6 2 Put under the coupling a suitable bowl of appropriate capacity to collect transm...

Page 67: ...L CHARACTERISTICS The ROTOFLUID fluid coupling operates with hydraulic oil as transmission fluid The applications of the fluid couplings in the natural environment must give priority to biodegradable mineral oils used for environmental protection CAUTION The couplings manufactured according to the ATEX directive and installed in explosive atmospheres shall use oils with higher flash temperature T ...

Page 68: ... Q TY MOTOR ABOVE COUPLING 20 K1 ø28 Lt 0 1 10 K1 ø24 Lt 0 125 30 K1 ø42 Lt 0 1 30 K1 ø42 Lt 0 400 30P K1 ø42 Lt 0 1 30P K1 ø42 Lt 0 950 40P K1 ø55 Lt 0 1 40P K1 ø55 Lt 0 850 20 K3 ø38 Lt 0 230 10 K3 ø28 Lt 0 1 25 K2 ø42 Lt 0 230 20 K3 ø38 Lt 0 1 30 K3 ø48 Lt 0 400 30 K3 ø48 Lt 0 1 40P K2 60 Lt 0 850 40P K2 ø60 Lt 0 1 55 K2 ø65 55 K3 ø75 Lt 1 8 Lt 1 8 55 K2 ø65 55 K3 ø75 Lt 1 8 Lt 1 8 65 K2 ø80 Lt...

Page 69: ...rea to access the coupling 7 1 2 Inspect the hydromechanic coupling and the installation space and check for oil leakage CAUTION Promptly remove any oil dripping and or leakage from the coupling or the soil DANGER OF SLIPPERY FLOOR CRASH AND OR FALL 7 1 3 Carefully inspect where possible the condition of the sealing of the coupling shaft in order to establish if it is necessary to substitute it 7 ...

Page 70: ...2a Manually turn the coupling until the oil screw plug reaches the angle inclination determined through the pre established calibration NOTE In case the couplings are equipped with plug and level indicator it is sufficient to position the coupling in the pre established filling position and check the oil level 7 2 2b Remove the plug or the device mounted in the oil filling hole and check the oil l...

Page 71: ...ling and drain the oil in excess of the calibration quantity Part 6 tranSMiSSion oil filling and calibration ROTOMEC USe and Maintenance handbook 54 ManUale d USo e ManUtenzione ROTOMEC T r a s m i s s i o n i d i P o T e n z a T r a s m i s s i o n i d i P o T e n z a In questa sezione vengono riportate le tabelle con le quantità di riempimento a livello in litri secondo una disposizione angolare...

Page 72: ... the location where the cou pling is installed and cleaning must be carried out in order to avoid the above described conditions CAUTION Before you start cleaning outside of the coupling A stop the motor and wait for the rotation components to stop B cut out power supply and apply a safety padlock C signal the operation under way D wait for the cooling if needed max 40 C 7 3 1 Open the accident pr...

Page 73: ...eturn spring is in good working order Make sure that device safety microswitch has not been tempered with it is in good working and the distance between the detector and the device is 2 mm 7 4 4 PM T09 UNIT T09 PM Make sure that the PM device in the coupling is in good operating conditions it is not damaged Make sure that the sensor of the T09 device has not been tampered with is in good operating...

Page 74: ...ning the ATEX couplings must be recorded to ensure the traceability of the replaced components and the state of the art technology of the hydromechanic coupling The components provided with ATEX certificate must be replaced with components having same characteristics and certificates in order not to down grade the coupling ATEX classification Part 7 Ordinary Maintenance ROTOMEC Use and Maintenance...

Page 75: ...75 P o w e r T r a n s m i s s i o n Date Operation Replaced Parts Operation Author Maintenance Manager Result Part 7 Ordinary Maintenance ROTOMEC Use and Maintenance Handbook ...

Page 76: ...K1 40 K1 40M K1 BETA Z X 20 Z X 25 Z X 30 Z X 40 Z X 40M Z X ALFA K 55 K2 K3 65 K2 75 K2 K3 85 K2 BETA X Z 55 Z X J H 65 Z X J H 75 Z X J H ALFA K2 K3 20 K3 25 K2 30 K3 40 K2 6 1 3 2 4 1 5 2 3 1 5 6 1 Hollow Shaft 2 Cover 3 Internal Pump 4 Female Turbine 5 Sectors 6 Rollers 7 Hub J 8 Hub H ROTOMEC 2 4 5 4 COUPLING COMPONENTS 6 3 4 1 5 2 6 3 7 8 Part 7 Ordinary Maintenance ROTOMEC Use and Maintenan...

Page 77: ...table air intake on the carter or on the guard 2 The carter is equipped with a cooling fan but it is out of order and it turns in opposite direction 3 The ambient temperature is still high or there are sources of heat next to the coupling 4 The driven machine is operating with excessive overload 5 Not enough transmission oil in the coupling 6 Oil is leaking from the hydromechanic coupling 7 Too fr...

Page 78: ...ling is damaged due to foreign bodies under the mim oil seals 6 Inadequate gaskets are mounted on the coupling 7 The screws on the coupling crown are not correctly tightened 8 The coupling shells cracked or broke because of crashes or internal overpressure FAULT THE COUPLING VIBRATES OR IT IS NOISY Possibly causes to be checked 1 The components connected to the coupling are not aligned or rotate o...

Page 79: ...or shaft on the blower side 9 1 5 Screw in the extractor in the hole of the coupling keeping into account that the extraction system S E can be used if the couplings are equipped with bored shaft sizes 70P to 85P Otherwise use the V E extraction system 9 1 6 Unscrew and remove one of the screws set in the crown of the coupling and insert the suitable hoisting device as foreseen by the manufacturer...

Page 80: ...5 Remove the seeger ring of the shielded bearing placed on the side of the threaded extraction hole of the coupling 9 2 1c COUPLING SIZE 75 85 Remove the seeger ring from the mim seal placed on the side of the threaded extraction hole CAUTION RISK OF SPLASHES AND SEAL EJECTION 9 2 2 To remove the mim seal use a screwdriver or as an alternative position a protective cloth on the shaft at the mim se...

Page 81: ...nic coupling shells 9 2 5 After the opening of the coupling it is possible to clean it inside and or replace any worn parts with original WESTCAR spare parts 9 2 6 To reassemble the coupling follow the reverse sequence repositioning the mim seals with their edge inwards without deforming it The opening of the coupling and the spare part replacement have thus ended 9 2 3 9 2 4 9 2 6 Part 9 Extraord...

Page 82: ...D IDENTIFICATION CODE of the coupling shown on the identification Plate To submit a request for FUSIBLE PLUG or EXPANDABLE TRIP PLUG KITS also specify the triggering temperature For any further information on single components of the coupling you may request the SPARE PART DRAWINGS specifying the ROTOMEC coupling model Kit of gaskets NBR Bearing Kit Fusible Plug Kit Kit of gaskets VITON Seeger Kit...

Page 83: ... the materials composing it as follows 10 2 1 Adopt measures to collect any transmission oil leakage in appropriate airtight containers CAUTION Do not spill exhausted oils in the environment but instruct authorized waste collection com panies to dispose of them DANGER OF ENVIRONMENTAL POLLUTION 10 2 2 The TF and TEs are to be removed from the coupling and require special handling and disposal proc...

Page 84: ... Canada Chile China Colombia Croatia Czech Republic Denmark Egypt Estonia Finland France Germany Great Britain Greece Holland Iran Korea Latvia Lithuania Macedonia Morocco New Zealand Norway Pakistan Peru Poland Portugal Romania Russia Serbia Singapore Slovak Republic Slovenia South Africa Spain Sweden Thailand Turkey USA ...

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Summary of Contents for ROTOMEC ALFA

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WESTCAR ROTOMEC ALFA, Original Instructions Manual, Page: 3 / 84

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Summary of Contents for ROTOMEC ALFA

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