eickhoff gearbox operating manual

G 046330XA 17.12.01

Operating Manual

Power Transmission Division

EnronWind 1.5 / 70.53-stage Helical Planetary Gearbox CPNHZ-195

Part number: G 046330XAGearbox type: 3-stage helical planetary gearboxGearbox No.:Order No.:Model: 2001Revision: 0

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Contents

1 INTRODUCTION ........................................................................................................................................ 3

1.1 LEGAL PROVISIONS................................................................................................................................ 31.2 THE OPERATING MANUAL....................................................................................................................... 4

2 SAFETY INSTRUCTIONS.......................................................................................................................... 8

2.1 GENERAL SAFETY INSTRUCTIONS ........................................................................................................... 82.2 SAFETY INSTRUCTIONS FOR TRANSPORT .............................................................................................. 102.3 SAFETY INSTRUCTIONS FOR ASSEMBLY ................................................................................................ 102.4 SAFETY INSTRUCTIONS FOR STARTING-UP ............................................................................................ 112.5 SAFETY INSTRUCTIONS FOR MAINTENANCE........................................................................................... 122.6 SAFETY INSTRUCTIONS FOR WASTE DISPOSAL...................................................................................... 12

3 TECHNICAL DESCRIPTION ................................................................................................................... 13

3.1 SCOPE OF SUPPLY............................................................................................................................... 133.2 STATE AS SUPPLIED............................................................................................................................. 133.3 RATING PLATE..................................................................................................................................... 133.4 DESIGNATED USE ................................................................................................................................ 143.5 ARRANGEMENT AND PRINCIPLE OF OPERATION ..................................................................................... 143.6 LIMITS OF APPLICATION........................................................................................................................ 153.7 QUALITY ASSURANCE........................................................................................................................... 153.8 TECHNICAL DETAILS EW1.5 / 70.5....................................................................................................... 16

4 TRANSPORT AND STORAGE................................................................................................................ 17

4.1 TRANSPORT OF THE GEARBOX ............................................................................................................. 174.2 STORAGE OF THE GEARBOX ................................................................................................................. 17

5. ASSEMBLY AND STARTING-UP ........................................................................................................... 19

5.1 ASSEMBLY........................................................................................................................................... 195.2 COMMISSIONING .................................................................................................................................. 21

6 MAINTENANCE ....................................................................................................................................... 23

6.1 MAINTENANCE TABLE........................................................................................................................... 246.2 OIL ANALYSES AND OIL CHANGES ........................................................................................................ 246.3 CLEANING THE OIL FILTER.................................................................................................................... 286.4 CHANGING THE GREASE PACKING OF THE GEARBOX AND ROLLING BEARINGS ....................................... 286.5 SEALING OF THE HOUSING PARTING FACES AND COVERS...................................................................... 286.6 USE OF LOCTITE .................................................................................................................................. 286.7 TROUBLE SHOOTING TABLE.................................................................................................................. 29

7 ANNEX ..................................................................................................................................................... 30

7.1 SERVICE.............................................................................................................................................. 30

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7.2 COMPANY ADDRESS ............................................................................................................................ 307.3 AGENCIES ........................................................................................................................................... 317.4 MANUFACTURER’S DECLARATION ......................................................................................................... 32

8 DRAWINGS AND SPARE PARTS LIST ................................................................................................. 33

9 ACCESSORIES........................................................................................................................................ 34

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1 Introduction

1.1 Legal Provisions

ManufacturerEICKHOFF Maschinenfabrik GmbH

Hunscheidtstr. 176

D-44789 Bochum

Proper UseThe gearbox is designed exclusively for proper use as defined in this operatingmanual (see chapter 3 Designated Use).

Improper UseThe gearbox must not be used for applications other than provided for in the chapteron Proper Use. Any other use is classified as improper use and may lead to:• injury to persons or death• damage to the system• damage to other material property

LiabilityThe information, details and notes contained in this operating manual reflect the lateststate on the day of issue. Technical modifications are reserved within the bounds ofthe further development of the gearbox. No claims shall therefore be raised for alreadydelivered gearboxes on the grounds of specifications, illustrations or descriptions con-tained in this operating manual.

No liability is assumed for damage or functional disorders caused by:• disregard of the operating manual• operator's mistakes• inexpert work on and with the gearbox• use of other than genuine OEM spare parts or accessories of EICKHOFF

Maschinenfabrik GmbH• unauthorized conversions or modifications of the gearbox by the user or his/her

personnel

EICKHOFF Maschinenfabrik GmbH accept liability for faults and omissions within thebounds of the warranty obligations entered into according to the main contract. Claimsfor damages, from whatever legal grounds they may be deduced, are excluded there-from.

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WarrantyWarranty claims shall be brought to the notice of EICKHOFF Maschinenfabrik GmbHimmediately after the fault or defect has been located by indicating the part number,the gearbox type and the serial number.

During the warranty period the gearbox must only be opened in the presence ofan EICKHOFF representative or following EICKHOFF'S prior consent.Wear parts are excepted from the warranty.

The warranty expires in the case of:• improper use of the gearbox• inexpert work on and with the gearbox• use of inadmissible operating means• use of other than genuine OEM spare and wear parts of EICKHOFF

Maschinenfabrik GmbH• opening the gearbox during the warranty period without the prior consent of

EICKHOFF Maschinenfabrik GmbH• draining oil from the gearbox in the case of damage

CopyrightThis operating manual and all information contained therein are protected by copy-right. Duplication (including extracts) or conveying to third parties, disclosure orexploitation of its contents are not permissible without the explicit consent of EICKHOFFMaschinenfabrik GmbH.

© Copyright 1999 by EICKHOFF Maschinenfabrik GmbH

1.2 The Operating ManualThe details and notes contained in the present operating manual shall enable theactive personnel to work safely, properly and efficiently on and with the gearbox. It isonly when the contents of the operating manual is fully understood and observed that• hazards are avoided• repair cost and downtimes are kept to a minimum and• reliability and service life of the gearbox are increased.For easy reference, the following paragraphs explain the systematics and rules as wellas the textual and pictorial definitions applied in this manual.

Definition of TermsThis operating manual uses a number of important terms which are defined below:

GearboxThe term "gearbox" as used in this manual shall mean the complete gearbox (seechapter 3 Scope of Supply).

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EICKHOFF

EICKHOFF Maschinenfabrik GmbH is the manufacturer of the gearbox and shall becalled EICKHOFF hereinafter.

UserThe user shall be every natural or legal person who operates the gearbox or givesinstructions to operate the gearbox on his/her behalf.

Operating PersonnelOperating personnel shall be persons who have been charged with and instructed inthe operation of the gearbox. The operating personnel is authorized to carry outsimple maintenance such as cleaning the gearbox on the outside.

Persons shall be deemed instructed when they have been

• informed of the tasks assigned to them and have received correspondingtraining, as necessary.

• warned of the potential hazards arising from inexpert handling• made familiar with the necessary safety devices, safety precautions, accident

prevention regulations, pertinent rules and service conditions.For the required instruction duties and authority, see chapter 2 General SafetyInstructions.

Skilled PersonnelSkilled personnel shall be persons having• qualifications as machine fitters (recognized occupation: industrial mechanic) or

equivalent qualifications and• the ability to assess and perform, in a professional way, the tasks assigned to

them owing to their professional training, knowledge and experience.The skilled personnel shall be familiar with the accident prevention regulations,pertinent rules and service conditions.

EICKHOFF Maschinenfabrik GmbH PersonnelEICKHOFF personnel shall be skilled personnel employed by EICKHOFF.

Remaining HazardsRemaining hazards shall be latent risks arising from the use of the gearbox.

Example:

Hazard of burns from hot components after the gearbox has been switched off.

Protective ClothingProtective clothing shall be the personal protective gear that protects the body againstthe hazards arising at work. The protective clothing must comply with the require-ments of the Equipment Safety Act.

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The circumstances under which protective clothing must and shall be worn are set outin the applicable local accident prevention regulations.

Pictorial Representations and Textual DisplaysThe following pictograms and symbols are used in this operating manual to givesalience to important information.

General HazardMakes reference to safety instructions which must by all means be observed to avoidinjury to persons and to which no specific pictogram (e.g. one of the following) canbe assigned.

High Electric VoltageWarns of the hazard of electric shock.

Hot ComponentsWarns of the hazard of burns when hot system components are touched.

Ecologically Harmful SubstancesWarns of the hazard arising from chemical substances unless the said substances aredisposed of in accordance with the applicable environmental rules and regulations.

Safety Related NoteMakes reference to statements on how to work safely on and with the gearbox.

Supplementary InformationMakes reference to practical hints and useful information.

Two different symbols are used in this operating manual:

This symbol indicates individual work instructions which must be executedprecisely in the given order.

• This symbol indicates enumerations, the contents of which is of equal priority.

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Structure and Contents of the Safety InstructionsAll safety instructions contained in this operating manual are of uniform structure.

Essential Elements of a Safety InstructionEach safety instruction contains a number of essential elements:• a pictogram• a signal word indicating the level of the hazard• a statement on the type of the hazard and• a statement on how to avert the hazard.

The following signal words indicate the level of the hazard:

Dangerwarns of an imminent hazard to life and health of human beings. Possibleconsequences: death or serious injuries

Warningwarns of a potential hazard to life and health of human beings. Possibleconsequences: death or serious injuries

Attentionindicates a potential hazard to persons or material property. Possible consequences:Slight injuries to persons or damage to material property.

Noteindicates a potentially hazardous situation for material property or the environment.

Possible consequences:• damage to the gearbox itself• damage to the material property surrounding the gearbox• damage to the environment.

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2 Safety Instructions

2.1 General Safety InstructionsThe gearbox has been built in accordance with the applicable state-of-the-artstandards at the time of ordering and is deemed operationally safe as a whole.

Nevertheless, the use of the gearbox may constitute a risk when• unauthorized and non-instructed personnel is working on and with the gearbox

or• the gearbox is subject to improper use.

In such a case the following are at risk:• persons• the gearbox and• other material property of the user.

Safety of the GearboxThe following must be observed when working on and with the gearbox:• the applicable rules and regulations (e.g. VDE standards)• the applicable accident prevention regulations (UVV)• the pertinent directives• the applicable environmental protection laws.The gearbox must be used in a perfect condition only. This includes the prerequisitethat safety devices of the gearbox are in place and fully functional. In the event offunctional disorders or defects, the gearbox must be withdrawn immediately fromservice, and the said malfunction must be reported to the user's authorized supervisor.

The gearbox must not be restarted until the perfect function of the gearbox is re-established.

The safety devices must neither be removed nor deactivated. Where safety deviceshave to be removed for maintenance after all, they must be refitted immediately uponcompletion of the work. All safety devices must be checked for proper operationbefore the gearbox is started.

NoteAdditions to and/or modifications and conversions of the gearbox which may affectsafety are prohibited in general unless EICKHOFF's written consent has been obtained.The same applies to the installation and calibration of safety devices and to weldingload bearing components.

Genuine O.E.M. spares shall be used exclusively for gearbox component changes.Only O.E.M. spares keep the gearbox fully functional and safe.

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Operating ManualThe present operating manual primarily aims at ensuring safety-conscious working onand with the gearbox. It contains safety instructions which must by all means beobserved.

The operating manual must• be read and understood by all persons working on and with the gearbox before

starting work• always be available at the place of use of the gearbox and must be stowed at a

designated location• always be complete and kept in a legible condition.Should this operating manual or parts thereof not be fully understood, work shall notbe started. Ask the skilled personnel of• the user or• EICKHOFF

before you risk exposing yourself to a potentially hazardous situation.

Duties of the UserThe user has to fulfil a number of duties towards his/her personnel.

The user is bound• to supplement the operating manual with instructions containing the national

accident prevention regulations and environmental protection laws• to familiarize the personnel with all relevant regulations, directives and laws, as

necessary• to verify that all relevant regulations, directives and laws are observed• to have the personnel instructed in the proper way of working on and with the

gearbox• to clearly define the responsibilities for assembly, starting-up and maintenance

of the gearbox• to verify that the defined responsibilities are actually respected• to verify at regular intervals that his/her personnel operates the gearbox in a

safety- and danger-conscious manner in accordance with the operating manualand

• to make sure that the personnel has read and understood the operating manual,and the chapter on Safety Instructions in particular. The user of the gearboxshould seek a written confirmation to this effect from the personnel.

Active PersonnelOnly authorized and instructed personnel shall be allowed to work on and with thegearbox. Unauthorized persons must be prohibited from operating the gearbox. Thefollowing work must be performed by skilled personnel only:• assembly• starting-up• maintenance.

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The responsible superior shall instruct the operating personnel in safety at workmatters at regular intervals not exceeding one year. The successfully completedinstruction course shall be placed on record and signed by the instructed personnel.

The operating personnel is bound to report any anomalies in the operating behaviourof the gearbox immediately to the responsible superior. Compliance with this require-ment is absolutely imperative in cases where the safety of the gearbox is no longerensured.

The personnel working on and with the gearbox must have long hair tied back orotherwise secured. Garments must be close-fitting, and jewellery - such as rings -must not be worn. The personnel must use their personal protective gear as neces-sary and as prescribed by the applicable rules.

2.2 Safety Instructions for TransportWarningHazard arising from falling transport objects

The transport of the gearbox must be carried out by skilled personnel only.

Use only transport equipment and transport aids which

• comply with the safety requirements and• are designed for the respective loads.• The gearbox must be lifted and transported exclusively at the marked attach-

ment points provided for this purpose.• Before initiating transport to the customer's site, it must be ensured that all

transport routes are clear of obstacles.

NoteDamage to the gearbox by temperature variations

Do not expose the gearbox to excessive temperature variations during transport toavoid condensing. Protect the gearbox against humidity using tarpaulins for transport.

2.3 Safety Instructions for AssemblyAttentionHazard arising from inexpert work on the gearbox

Assembly, installation and test run (commissioning) of the gearbox must be carried outby skilled personnel only.

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DangerHazard arising from high electric voltage

Assembly and installation of the electrical components and their testing must becarried out by skilled personnel (electrical engineers) only.

NoteBefore starting up the gearbox, check all lines and bolted connections for tight fit,leakage and externally discernible damage.

2.4 Safety Instructions for Starting-upWarningHazard arising from inexpert work on and with the gearbox. Hazard arising fromimproper use of the gearbox.• Starting up of the gearbox must be carried out by authorized and instructed

skilled personnel only.• The gearbox must be used in a perfect condition only. All safety devices of the

gearbox must be in place and fully functional. In the event of defects orfunctional disorders, the gearbox (or the system in which the gearbox isintegrated) must be immediately withdrawn from service and secured againstrestarting.

• The gearbox (or the system) must not be put into service until all defects orfunctional disorders are rectified and the gearbox is fully functional.

WarningDanger to the health or safety of persons arising from falling objects

Standing or working under suspended loads is strictly prohibited.

AttentionDamage to the gearbox by strewn tools or other objects

Make sure that no tools or other objects which are foreign to the system, are within thefunctional reach of the safety devices of the gearbox.

WarningHazard arising from the starting gearbox

Before starting up the gearbox make sure that no persons are exposed to the hazardarising from the starting gearbox.

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2.5 Safety Instructions for MaintenanceWarningHazard arising from inexpert maintenance of the gearbox• Maintenance of the gearbox must be carried out by skilled personnel only.• The maintenance work and intervals specified in this operating manual must be

strictly observed so that the gearbox is maintained in its operationally safecondition and provides a long service life.

• Switch off the system in which the gearbox is integrated, as prescribed andsecure it against restarting (e.g. by locking the key-operated switch or byremoval of the fuses in the power supply).

• Do not remove any safety devices from the gearbox. Where safety devicesneed to be removed for maintenance, they must be refitted upon completion ofthe work and checked for proper operation.

• Bolted connections separated for maintenance must always be firmly re-tightened and secured with Loctite.

NoteDamage to the gearbox by inexpert cleaning• Do not use any aggressive detergents.• Use only non-fraying cleaning rags.• Clean the gearbox from oil and contamination before starting maintenance.• Do not clean the oil filling area or the elastic shaft seals by means of a high

pressure cleaner.

2.6 Safety Instructions for Waste DisposalNotePollution of the environment by inexpert waste disposal• Keep suitable collecting pans and receptacles ready to hand to collect any

leaking operating fluid or spillage (such as gear oil).• All operating fluids, consumables and replacement parts must be disposed of in

a safe and environmentally protective manner in accordance with the applicableenvironmental legislation and regulations.

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3 Technical Description

3.1 Scope of SupplyThe gearbox is delivered by EICKHOFF in a completely mounted state as indicated inthe relevant order specification.The supplied gearbox shall be checked for completeness upon receipt. Any transportdamage and/or missing components shall be reported immediately in writing.

3.2 State as SuppliedThe gearbox is supplied in the following state:• The gearbox is supplied ready for operation, but without oil filling and without

assembly of the external add-on parts.• The gearbox has been preserved with the working oil prior to delivery. This

preservation is adequate for a storage period not exceeding 3 months fromreadiness for despatch and transport (no sea transport), subject to indoorstorage.

• Labyrinth seals and bearings of the cable bushing are already packed withgrease ex works.

• The gear housing and the housing parts are coated, internally and externally,with paint.

• The shaft extensions and the hollow shaft holes are coated with anti-rust paint.The anti-rust paint is saltwater-proof and tropicalized for 12 months.

3.3 Rating PlateThe gearbox type and the serial No. indicated on the rating plate and the partnumber stated in this operating manual (see chapter Introduction) should always bequoted in the case of enquiries. The rating plate is securely fixed to the gearbox andcontains the following details:• Gearbox type with part number and type designation• Model (column to the right of the type designation)• Serial No. (No.)• Power (P)• Operating torque (T2)• Ratio (i)• Input speed (n1) / Output speed (n2)• Oil quantity• Oil type

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3.4 Designated UseThe gearbox is used for power transmission between the rotor and the generator. Therotor speed is increased to the required speed of the generator.

Any other use or any use beyond the above limits is classified as improper use, inwhich case EICKHOFF shall not be held liable for resultant damage of any kind what-soever.

Proper use also takes it for granted that all instructions and details of the presentoperating manual be observed.

3.5 Arrangement and Principle of Operation

DesignThe three-stage helical planetary gearbox with two helical gear stages and oneplanetary stage is noise-optimized by profile and tooth trace corrections. The gearstages and the planetary stage have helical gear teeth. The sun gear of the planetarystage is floating for load compensation.

BearingsThe shafts are supported by amply dimensioned rolling bearings. The bearings of theoutput shaft are monitored by resistance thermometers.

After assembly the rotor shaft that does not form part of the scope of supply, and theinput planet carrier form a bearing unit together with the shrink disk where thecylindrical roller bearings of the planet carrier adopt the non-locating bearing function.

HousingThe multi-piece gear housing which is a supporting element, is of torsionally rigiddesign. A cast-on flange is provided on the input side and serves as a flexiblemounting to the machine carrier by means of shrunk-in pins. The brakes are bolted tocast-on faces on the output side.

The housing is fitted with an inspection hole cover on the output side for inspectionpurposes. The oil level glass and the oil level monitor are fitted on the same side.

LubricationThe gearbox has a combined splash and forced-feed lubrication system. The oil isfine-filtered through a separate filter system.

CoolingThe gear oil must be cooled by the cooling unit that forms part of the scope of supply,when the oil sump temperature reaches 60 °C or or when any bearing temperaturereaches 70 C.

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3.6 Limits of ApplicationDesign and operating range of the gearbox are based on the operating detailsspecified in chapter 3.8 Technical Details.

Consult EICKHOFF before using the gearbox outside its contractual limits of applicationor under different operating conditions.

Operating the gearbox at a higher load than the nominal load shortens the service lifeof the gearbox components, and that of the bearings in particular. In addition, perman-ently contaminated oil having a contamination level of 19/17/14 acc. to ISO 4406 leadsto premature bearing failure.

Reading Measuring Point Signal Type Normal ALARMOFF (2)

temperature (T0) oil sump switch 45°C–70°C (1) > 85°Ctemperature (T1) oil sump Pt 100 45°C–70°C (1) > 85°Ctemperature (T2) HSS - A Pt 100 60°C–85°C > 95°Ctemperature (T3) HSS - B Pt 100 60°C–85°C > 95°Coil pressure (p1) distributor digital 1.5 - 5.0bar < 0.5 bardifferential pressure (p2) clogging indicator switch < 2 bar (4) > 2 bar(4)

Additional Units ON OFF Commentcooler/fan motor T1 > 60°C

T2;T3 > 70°C T1 < 55 °CT2;T3 < 65°C

oil sump = T1HSS - A;B = T2;T3

heater in the oil sump (3) T1 < = 5°C T1 > 10-15 °C oil sump = T1

(1) The temperature rise of the gearbox varies as a function of the operating conditions. At ambienttemperatures ranging from 0°C to 30°C, the normal continuous temperatures of the oil bath will liebetween 50°C and 65°C.

(2) The wind turbine must be switched off!

(3) To expedite heating up at oil temperatures of T1 < 15°C, the lubricating oil system can be switched onas well.

(4) If the clogging indicator only responds at oil sump temperatures of T1 < 45°C (cold start), an elementchange is not necessary.

3.7 Quality AssuranceThe EICKHOFF quality system is audited in accordance with DIN ISO 9001 -design/development, production, installation and servicing - and in accordance withthe European Standard EN 29001 and the British Standards BS 5750.1.

The Certificate (Registration No. 21 143-03) has been awarded to EICKHOFF byDeutsche Gesellschaft zur Zertifizierung von Qualitätssicherungssystemen mbH –DQS (German Association for the Certification of Quality Systems).

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3.8 Technical Details EW1.5 / 70.5Use Drive of a Wind Turbine Power Plant

Gearbox model 3-stage helical planetary gearboxGearbox type CPNHZ-195Part number G046330XaType of drive three-blade rotorRotor diameter 65/70.5 mHub height 61.4 - 100 mRotor shaft gradient 4.0°

Identification

Wind velocity operation: 3 – 25 / 20 m/sDrive power 675 1660 1660 kWRatingsGenerator power 600 1500 1500 kWDimensions see drawings 009969G1FSizeWeight and packing dimensions see drawings G046330XAInput torque 792.6 kNmMax. input torque 2380.0 kNm (3xMn)Output torque 11.0 kNm

Torques

Max. output torque 33.0 kNm (3xMn)Input speed 11.0 20.0 22.0 r.p.m.Output speed 1000 1440 1584 r.p.m.Overspeed 28 r.p.m.

Rotationalspeeds

Direction of rotation clockwise (when looking at the rotor flange)Transmissionratio

1 : 71.766

Type of lubrication forced-feed lubrication and splash lubricationapprox. 35 l (cooling/lubricating circuit )Oil quantityapprox. 280 l (gearbox)

Lubrication

Oil type Optimol Optigear Synthetik A320Type Oil cooling by externally erected oil/air coolerHeat to be dissipated approx. 49 kW / Voil= 68 l/min

Cooling

Filter fineness 10 µm abs.Noise emission Sound pressure level in accordance with the specification

Operating site inland and onshorePlace of erection inside the ventilated nacelleAmbient temperature -20°C to +45°COpen air climate corrosive, saliferous atmosphere; drift sandPeriod of operation 24 h/dayDuty cycle 100 %

Operating site/conditions

Service life 20 years

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4 Transport and Storage

4.1 Transport of the GearboxAttentionDanger to the health or safety of persons or damage to the gearbox

Under no circumstance must the gearbox be lifted and transported on its shafts. Forlifting the gearbox, use the lifting eyes, lifting cams or 3-D load rings fitted to thehousing, or ropes which are to be tied around the housing. See the spare parts draw-ings for the permissible attachment points.

NoteDamage to the gearbox by temperature variations

Do not expose the gearbox to excessive temperature variations during transport toavoid condensing. Protect the gearbox against humidity using tarpaulins for transport.

AttentionPollution of the environment by spilling oil

The gearbox must be transported exclusively without oil to avoid spilling.

4.2 Storage of the GearboxNoteDamage by inexpert storage• The state of the gearbox as supplied must be taken due note of for storage (see

chapter 3.2 State as Supplied).• Store the gearbox in a vibration-free place as otherwise damage to the bearings

could occur.• Stacking up the gearboxes is not permissible.

Storage ConditionsThe gearbox must be stored indoors in general. If the actual storage period exceedsthe period stated in chapter State as Supplied, long-term preservation must beapplied.

If storage extends over several years, further preservations may become necessarydepending on the state of the gearbox.

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After very long storage periods - but after 5 years at the latest - a general inspectionmust be conducted before starting up the gearbox.

Temporary Storage / Withdrawal from ServiceCheck the oil level at regular 1-month intervals and turn the gearbox by hand as far aspracticable. When withdrawal from service lasted for more than 1 year, the gear oilmust be changed before the gearbox may be put into service again.

InspectionThe said general inspection can be conducted by EICKHOFF, upon request, either attheir works or - when the gearbox is still integrated in the system - at the user's site.

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5. Assembly and Starting-up

5.1 AssemblyObserve the safety instructions contained in chapter 2 for assembly.

Adequate transport equipment and transport aids must be on hand for transporting thegearbox. The transport routes to the place of erection of the gearbox must be clear ofobstacles.

The place of erection of the gearbox must be clean and dry.

Mounting the gearboxHintWhen mounting the gearbox be careful• to keep the holes for venting, oil filling and draining as well as the oil level

indicator easily accessible.• not to impede the air flow on the suction and pressure sides in the case of fan-

cooled gearboxes.

AttentionWhen using solvents and detergents it is imperative to ensure that contact with shaftseals be avoided.

WarningExplosion hazard

Provisions shall be made for adequate ventilation when using solvents. Do not smoke.

NoteUnder no circumstance must the rust preventative be rubbed off the shaft extensionsor centre holes with emery.

NoteMount the connecting elements exclusively using the front side threaded holes (acc. toDIN 332) in the shaft ends.

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Remove the rust preventative from the shaft extensions and centre holes usinga solvent before mounting the connecting elements.

Check fits and edges of the shafts for damage. Retouch affected parts, if any,using suitable tools and clean again.

Clean the surfaces to be joined of the shrink disk connection between the rotorshaft and the hollow shaft of the gearbox and wash them clean using solventand finally lime milk.

Connect the rotor shaft and the hollow shaft of the gearbox by means of theshrink disk that is part of the scope of supply. See also the mounting instruc-tions for the shrink disk in chapter Accessories.

Place the gearbox with the flexible bushes and the clamping halves on top ofthe machine frame.

Aligning the GearboxAttentionDamage to the bearings by excessive axial load

The inner axial clearance of the non-locating bearing of the rotor shaft must be 1.5mmon either side as otherwise the cylindrical roller bearings of the rotor shaft would beexposed to axial load. This may lead to premature failure of the bearings.

While aligning it should be taken into account that the fixed bearing of the rotorshaft has an essential inherent axial clearance.

HintAdditional loads due to misalignment shorten the service life of the gearbox and maylead to premature failure. Align the gearbox without angular displacement to ensuresmooth and low-vibration operation.

The permissible tolerances for angular and axial displacement of the coupling on theoutput side are specified in the manufacturer's documentation (see chapter Acces-sories).

Mounting on the Machine FrameMount the gearbox and the fixed bearing housing of the rotor shaft to the machineframe using the clamping halves while taking due note of the specified bolt tighteningtorques (see chapter Drawings and Spare Parts List).

After AssemblyCheck the corrosion preventative and the paint of the gearbox for damage and retouchwhere necessary.

Labels affixed to the gearbox such as the rating plate or the arrow indicating thedirection of rotation, shall be taken due note of. They must be free of paint or dirt.Missing labels must be replaced.

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5.2 Commissioning

PreservationThe gearbox that was rinsed after the test run, is supplied without oil filling. The clean-liness achieved corresponds to a cleanliness grade of 17/15/12 according to ISO 4406(1987).

Greasing pointsThe greasing points of the gearbox are already packed with the specified greasequantity and quality ex works. The bearings of the cable bushing and the 'V'-rings aregreased for life.

NoteThe greasing points of the 'V' rings must be re-packed when storage extends over oneyear.

Oil FillingFill the gearbox with the specified oil (see chapter 6 Maintenance).

For the oil quantity and oil type see chapter 3.8 Technical Details. The oil quantityindicated therein is for guidance only. The decisive criterion is the oil level in themounting position.

The oil is filled in through the oil drain cock or the filling hole in the inspection holecover by means of a filling unit (oil filter fineness < 5µ absolute).

NoteIn the mounting position the oil level must be up to the middle of the oil level indicator

Overfilling beyond the maximum mark leads to additional heating and foaming of theoil and to leakage of the rotor shaft seal. Note that the cooling circuit takes approx.30 l of oil.

AttentionDamage to the gearbox by contaminated oil

No fresh oil that stems directly from the barrel must be filled into the gearbox. Therequired cleanliness grade of 17/15/12 according to ISO 4406 (1987) is only ensuredby additional filtration. The inspection hole cover must only be opened for inspectionpurposes as otherwise contamination cannot be excluded.

NotePollution of the environment by spilled oil

Any oil spilled must be removed immediately using oil binder.

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Make sure that the gearbox is exclusively operated in the permissible directionof rotation.

Verify that the gearbox is properly mounted.

Make sure that guards for rotating parts (such as couplings, shafts, brakes) areavailable.

Forced-Feed Lubrication SystemsVerify that an adequate oil pressure from 1.0 to 5.0 bar is applied at operating tem-perature. A pressure gauge and a pressure sensor are provided for monitoring.

HintFor adjusting the monitoring and control devices see the operating instructions of themanufacturer.

Before Commissioning/Starting-up Check the gearbox for proper bolting and for the correct direction of rotation.

Check the oil level.

Heat the gear oil, if required, up to 10°C by switching the heater on.

Check the oil pressure of the forced-feed lubrication system.

Start the system.

During the Running-in Period Let the gearbox run at 30% of the nominal load for 100 hours, thereafter at 60%

of the nominal load for 50 hours and finally at 80% for another 50 hours.

Check the oil and bearing temperatures permanently during the running-inperiod.

NoteThe drive must be removed immediately from service when anomalies in the operatingbehaviour of the gearbox are found such as unusual gearbox noise or elevated bear-ing temperature.

AttentionIf anomalies such as elevated bearing temperature, tripping of the oil pressure sensoror leakages are found during operation, the system must be switched off instantan-eously. The cause of the anomaly should be identified as described in chapter 6.7Trouble Shooting Table. If no cause can be found you should contact our servicedepartment.

Operating Manual


G 046330XA 17.12.01 23

6 Maintenance

NoteMake sure throughout maintenance that• all bolts and nuts are tightened to the specified torques and secured with Loctite

"LV" and• internal bolts are secured with Loctite "SV".After each disassembly

• clean the screws and bolts and re-insert them with Loctite (see chapterApplication of Loctite).

Hint• Genuine O.E.M. spares as itemized in the pertinent spare parts list shall be

used exclusively for component changes (see chapter Drawings and SpareParts List).

• Warranty expires when unauthorized repairs are carried out during the warrantyperiod.

NotePollution of the environment by inexpert waste disposal

All operating fluids, consumables and replacement parts must be disposed of in a safeand environmentally protective manner in accordance with the applicable environ-mental legislation and regulations.

Operating Manual


G 046330XA 17.12.01 24

6.1 Maintenance Table

Inspection half-yearly

during theoil change

every1 - 2 years

Internal state and function of lubrication system

Leakage

Noise

Vibrations

Mounting of units

Breather

External state

State of tooth flanks

Internal state and function

Maintenance half-yearly

during theoil change

every1 - 2 years

Change oil filter insert

Gearbox - change oil See chapter 6.2 Oil Analyses andOil Changes

Gearbox - change greaseRegrease grease packed rolling bearings

See chapter 6.4 Changing theGrease Packing of the Gearbox andRolling Bearings

Clean screw plug magnets

Clean interior of the gearbox

Clean oil circulating system

6.2 Oil Analyses and Oil Changes

Oil analyses • First analysis after 12 months• Further analyses at half-yearly intervals

Oil changes Depending on the contamination level of the oil (analysis of oilsamples) but after 36 months at the latest.

Operating Manual


G 046330XA 17.12.01 25

Oil Sampling

General Notes:• A sample of the fresh oil must be taken after every oil change to determine the

reference value.• The oil sample must always be taken from the same point and under the same

conditions.• The sampling point must not lie in a zone where the oil is not circulating.• The sample must be taken when the machine is at operating temperature.• The sample containers used should always be new and in any case thoroughly

cleaned.• The sample containers must be identified by labels which contain the following

details:- Place of installation of the machine- Date of sampling- Time of sampling- Operating time since the last sampling- Name of the person having taken the sample

Oil samples may be taken, for example, from the mini-measuring connection in theflange piece between the pump and the oil filter by means of appropriate samplingdevices. The following procedure should be generally followed for any sampling pointson the gearbox:

Thoroughly clean the sampling point.

Put a collecting pan under the sampling point.

Connect the sampling device with sample container.

Take the sample.

Thoroughly close the sampling point.

Operating Manual


G 046330XA 17.12.01 26

Oil AnalysisThe analysis should cover the following parameters:

Parameter Limiting ValuesVisually clearTypical odour

Appearance

Product-specific colourViscosity 288 – 352 cSt at 40°CDensity Changes due to ageing in conjunction with a higher viscosityNeutralization number (NZ) 2.2 – 4.8 mg KOH/gIncrease of NZ versus thefresh oil sample

< 0.8 mg KOH/g

Water content ≤ 0.01 %Iron ≤ 800 ppm max.Copper ≤ 400 ppm max.Silicon ≤ 100 ppm max.Potassium ≤ 50 ppm max.Sodium ≤ 50 ppm maxChromium ≤ 20 ppm max.Calcium ≤ 20 ppm max.Magnesium ≤ 20 ppm max.Aluminium ≤ 15 ppm max.Tin ≤ 15 ppm max.Lead ≤ 10 ppm max.

Element analysis

Nickel ≤ 10 ppm maxMetal particles ≤ 35 mg/mlParticle quantity (PQ) index ≤ 60

The above oil limiting values serve for guidance and provide the basis for a preciseassessment as to whether single values may be exceeded.

Oil ChangeThe gear oil must be drained completely and replaced with fresh oil on expiry of the oilchange interval and/or as a result of the oil analyses. If heavy contamination is foundthe gearbox must be rinsed with diesel fuel and/or flushing oil. If the oil contaminationrises to a permanent value of 19/17/14 according to ISO 4406, premature failure of thebearings is to be expected.

Operating Manual


G 046330XA 17.12.01 27

NotePollution of the environment by inexpert waste disposal

All operating fluids, consumables and replacement parts must be disposed of in a safeand environmentally protective manner in accordance with the applicable environ-mental legislation and regulations.

WarningDanger to the health or safety of persons arising from inadvertent starting

The system must be secured against inadvertent starting prior to the oil change. A cor-responding warning label must be attached to the starting facility.

WarningHazard of burns from hot components or operating fluids

The oil bath may attain temperatures as high as 90 °C with the result that also thegearbox components may be subjected to a high temperature rise. Wear safety gloveswhere necessary when conducting the oil change.

AttentionDamage to the gearbox by contamination

Proper operation and the service life of the gearbox as a whole are affected whencontaminants penetrate into the oil circuit. Therefore pay attention during maintenanceof the gearbox that no fibres of cleaning rags, sand or foreign material enter the oilcircuit.

NoteThe oil must be drained at operating temperature.

Shut down and secure the system.

Connect the oil collecting pan to the oil drain cock using a hose.

Open the screw plug and the drain cock.

Fill in the specified oil type and quantity through the oil drain cock by means of afilling unit (oil filter fineness < 5µ absolute).

Close screw plug and oil drain cock.

Operating Manual


G 046330XA 17.12.01 28

NoteIn the mounting position the oil level must be up to the middle of the oil level indicator

Overfilling beyond the maximum mark leads to additional heating and foaming of theoil and to leakage of the rotor shaft seal. Note that the cooling circuit takes approx.30 l of oil.

6.3 Cleaning the Oil FilterPlease note the operating instructions of the oil filter manufacturer.

6.4 Changing the Grease Packing of the Gearboxand Rolling BearingsThe rolling bearings and 'V'-rings in question are already packed with grease upon de-livery. The grease packing is sufficient for the entire bearing life so that regreasing isnot necessary.

6.5 Sealing of the Housing Parting Faces and CoversThe parting faces of the housing and the fitting surfaces of the covers are sealed withHYLOMAR SQ 32/M jointing compound against escaping oil. The inspection holecover is fitted with a paper seal which must be checked before re-mounting the coverand changed where necessary.

All sealing surfaces must be cleaned and re-sealed with HYLOMAR or an equivalentjointing compound after every disassembly and re-assembly.

6.6 Use of LoctiteThe Loctite products referred to in this operating manual are used where bolted con-nections shall be secured against undesired separation (e.g. due to vibrations orshock loads).

Application of the Adhesive Apply the adhesive to one contact surface only (preferably to that of the bolt

thread). Be careful to wet the overall thread length.

For Blind Hole Threads In the case of blind hole threads it is essential that the adhesive be applied to

the bottom of the threaded hole. The quantity of the adhesive shall be such thatthe displaced adhesive fills in the overall thread length after assembly.

When screwing the bolt in, screw it back by a number of turns so that theentrapped compressed air can escape.

Operating Manual


G 046330XA 17.12.01 29

For Bolted ConnectionsType of

ConnectionNominal

Thread Size[mm]

Product Information Notes on the Drawings

Loctite product 243Colour: blueBreakaway torque DIN 54454,M10 bolts: 14-34 Nm

Separable,medium strength

(connection can beseparated usingstandard tools) Designed for a temperature range of:

- 55 ° to +150 °C

Identification of the secured bolts:* secured as per GEN 6 0 00812.06 "LV“adjacent to the drawing title block

Loctite product 262Colour: redBreakaway torque DIN 54454,M10 bolts: 15-50 Nm

Inseparable,high strength

(connection thatneed not be

separated later on)

< 36

Designed for a temperature range of:- 55 ° to +150 °C

Identification of the secured bolts:* secured as per GEN 6 0 00812.06 "SV“adjacent to the title block

6.7 Trouble Shooting TableAnomaly Potential Cause Remedy

Gear oil level too low Check oil level when the system is stationary.Top up oil, if required.

Oil pump defective Check pump. Change, if required.Oil overaged Change oil.Rolling bearing defective Contact service department.

Check bearing. Shut down system, if required.

Elevated rolling bearingtemperature

Cooler defective Contact service department.Shut down system, if required.

Gear mesh damage Contact service department.Check gear meshes. Shut down system, if required.

Excessive bearing clearance Contact service department.Check bearing clearance and adjust, if required.

Unusual gearbox noise

Defective bearing Contact service department.Check bearing. Shut down system, if required.

Defective couplingLouder noise in the area ofthe add-on parts than usual Defect in the generator

Gear oil level too high Check oil level when the system is stationary.Lower gear oil level, if required.

Oil overaged Change oil.Oil heavily contaminated Change oil.Oil pump defective Check pump. Change, if required.

Elevated oil sumptemperature

Cooler defective Contact service department.Shut down system, if required.

Pressure sensor triggersalarm

Oil pressure < 0.5 bar Check oil level. Top up oil, if required.Check oil pump. Change, if required.Check oil filter. Change, if required.Check pressure sensor.Measure oil pressure at the mini-measuring connectionusing a pressure gauge.

!G

!GENTITL

!GENTITL

!GENTITLE-LLBlatt Nr. / sheet no:Blätter / sheets:

Ausgestellt /

Rev.:

drawn:

217981 C3Getriebe EW 1.5 Serie

gearbox EW 1.5SP

10.10.2001

6.6.2001

2

ÖlkühlerGetriebe Getriebe

Schmierpumpe Heizpatrone 1 Heizpatrone 2

32 33 3427 28 29 30 3113 14 15 16 1917 2018 21 22 23 24 25 261 2 3 4 5 6 7 8 9 10 11 12

PEU1V1W1

V2 U2 W2

M

W2V2 U2

U1

M

W1 V1 PE

-2R1

1 4 PE

-2R2

1 4 PE

-2M1 -2M2

PE PE PE PE PE

GX2

(-2M1) (-2M2) (-2R1) (-2R2)

(-1R2)

Eingang (oben)

(-1B2) (-1S2) (-1R1) (-1R3)

ground

-1B3-1R2-1R1-1S2

GX11 2 3 4 5

oil level oil-pressure switch

oil

bearing A

2

1

2

1

106 7 98 1311 12 1514

4

22

1 - 1+

3

16 17 18 19 2220 21 23 24

gearbox

temperature temperature

gearbox

Abschirmung

GetriebeÖlstand

Lager ATemperatur

GetriebeÖl-Druckschalter

TemperaturÖlsumpf

gearboxlubricating pumpoil cooler

gearbox heaterheaterelement 2element 1

input (on top)

input (on top)Eingang (oben)

W103W102

W104W105

W201W202

W203W204

Nicht benutzte Einführungsbohrungen mitzugehörigen Verschlusstopfen verschliessen.Close unused entry holes withcorrespondending closing plugs.

W204W201 W202 W203

W106W101 W103W102 W104

1 2 1 2 1 2 1 2 3

1 2gr/ge

1 2gr/ge

gr/ge

blbrsw

gr/ge

blbrsw

2

-1R3

1

2

W106

1

Lager B

bearing B

Temperatur

temperature

W105(-1B3)Übertemperatur

Getriebe

gearboxtemperatureoverload

W107(-1S4)

Anschlussplan/connection diagram

2625 27

PE

NAME DAT.REVI

SION

9.9.01SPSP 10.10.01

-1B2

W101

1

1P

2 3

32

verschmutzungFeinfilter-Getriebe

fine clear filtergearbox

4

1

-1S4

-T2

1

W107

2 3

3635

Operating Manual


G 046330XA 17.12.01 34

9 Accessories

E_NF1310_2SO.doc/16.02.2001/B. Schön

Hydac Filtertechnik GmbH Bärbel Schön / Abt. FFVIPostfach 1251 Telefon (06897) 509-784D-66272 Sulzbach/Saar Telefax (06897) 509-300Industriegebiet E-Mail: [email protected] Sulzbach/Saar

Low Pressure Filter

NF BN/HC 1310 D P 10 D 2.0 /-V-L24-SF50Artikel-Nr.: 01274404

SPARE PARTS LISTMAINTENANCE INSTRUCTIONSThe warranty offered pursuantto our Terms of Sale andDelivery is applicable only in theevent that original HYDACcomponents are used and workis carried out solely by properlytrained and qualified personnel.

Seite 2

INDEX

1. MAINTENANCE UNSTRUCTIONS1.1 Safety Instructions1.2 Installation1.3 Commissioning1.4 Equipment Requiered For Changing The Element1.5 Torque Ratuings For Clogging Indicators

2. MAINTENANCE2.1 General2.2 Maintenance Procedures2.3 Interval Between Chanfing Elements

3. CHANGING THE ELEMENT3.1 Removing The Element3.2 Fitting The Element

4. SPARE PARTS4.1 Spare Parts Drawing NF 13104.2 Spare Parts List NF 1310

Seite 3

1. Maintenance instruktions

1.1 Safety Remarks-Maintenance work may only be performed by properly trained personnel using the right tools for the job.

-The operator/owner is to ensure adherence to the National Water Resources Act as well as local water resources laws and other related regulations.

-The hydraulic system is to always be shut down when performing work on filters. To this end, the filter must be depressurized.

-Adherence is to be maintained to statutory accident prevention regulations, safety regulations and safety data sheets for fluids.

-When working directly on or in the vicinity of hydraulic systems, there is to be no smoking or open flames/fire, with every effort being taken to prevent the generation of sparks.

-Collecting basins, suction/extraction equipment and binding agents are to be made available.

-Hydraulic media and water-polluting fluids must not be allowed to soak into the soil, seep into bodies of water or the sewage system. Ensure that hydraulic media are disposed of in an environmentally safe manner. Adherence is to be maintained to pertinent national and local regulations pertaining to groundwater protection, disposal of waste/spent oil and (hazardous) waste.

-Work on filters may involve leaking hot oil which may cause injury and scalding as result of its high pressure and/or temperature.

1.2 Installation

Before installing the filter in the hydraulic system check to see whether the permissible operating pressureof the system corresponds to the value indicated on the rating plate.

1.3 Commissioning

Check whether the correct filter elements (1 and 2) is fitted. Screw on demed head again.Switch on hydraulic system and check filter for leakage. Vent filter at a suitable place in the system.

1.4 Tools Required for Maintenance Work

Size VD 0 A.1

SW

VR 0 A.0

SWNF 1310 SW 27 SW 19

1.5 Torque Ratings For Clogging Indicators

TYPE max. MomentVD ... 25 NmVR ... 25 Nm

Seite 4

2. MAINTENANCE

2.1 General

This section describes maintenance work which should be carried out periodically.The operational safety and life expectancy of the filter, and whether it is ready foruse, depend to a large degree on regular and careful maintenance.

2.2 Maintenance Procedures

-Spare parts must fulfil the technical requirements specified by the manufcturer. This is always guaranteed for HYDAC original spares.

-Keep tools, working area and equipment clean.

-After disassembling the filter clean all components, check for damage or wear, and replace, if necessary.

-When replacing a filter element make sure that everything is kept as clean and dirtfree as possible in order to prevent the filter from being contaminated.

2.3 Interval Between Changing Elements

Based on a dirt volume of 20 mg/hour the calculated life time of the element is about 9500hours. The real life time may differ from this value depending on the type of contamination.(Dirt holding capacity of element 1300 R 010 BN3HC /-V is 190g ISOMTD at 2 bar ∆p, accordingto ISO 4572).

The filter element can monitored by equipping the filter it with a clogging indicator(optical/electrical).

When the clogging indicator responds, the filter element has to be changed or cleanedimmediately.

If no clogging indicator is fitted, we recommend that the filter elements are changed at pre-defined intervals, however at least once a year (the element change frequency depends on thefilter design and the conditions to which the filter is subjected). When the filter element issubjected to high dynamic loading it may prove necessary to change the element morefrequently. The same applies to commissioning, repair work, oil changes etc. in the hydraulicsystem.

Standard clogging indicators respond only, if there is a flow through the filter. As to electricalclogging indicators, the signal can also be processed and indicated on the control panelcontinuously until acknowledging the fault by eliminating it (i.e. changing the filter element andcold-starting the system).

If the clogging indicator only responds upon cold-starting, the filter element may not yet requirechanging.

Seite 5

3. CHANGING THE ELEMENT

3.1 Removing The Element

1. Switch off hydraulic system.

2. Loosen the vent screw (3) of the cover plate (A). Remove oil drain plug (4). Collect oil in a container.

3. Unscrew the cover plate (A).

4. Pull out the filter element (1) by handle (Examine the surface of the filter element for contaminationresidue and large-sized particles. The may be an indication of damage to components.)

5. Pull out filter element (2), surface of the filter element for contamination residue and large-sizedparticles. Replace or clean the filter element (only W, W/HC and V elements can be cleaned).Separate cleaning instructions are available on request.

6. Clean the housing and cover plate as may be necessary.

7. Check the filter for mechanical damage/wear, paying special attention to the apperance of sealingsurfaces.

8. Check the o-rings. If necessary, change them.

3.2 Fitting The Element

1. Moisten the sealing surfaces on the filter housing and the cover plate including the seals with cleanhydraulic medium as needed.

2. When fitting a new filter element check that the designation of the new filter element corresponds tothat of the old element.

3. Place the filter element (2) carefully onto the filter element pin in the cover plate (B).

4. Place the filter element (1) carefully onto the filter element pin in the cover plate (B).

5. Screw on domed head (A).

6. Screw in oil drain plug (4).

7. Switch on the hydraulic system, and vent filter at an appropriate place in the system.

8. Check filter for leakage.

NOTE: Filter elements which cannot be cleaned must be disposed of in accordance withenvironmental regulations.

Seite 6

4. SPARE PARTS

4.1 Spare Parts Drawing NF BN/HC 1310 D P 10 D 2.0 /-V-L24-SF50

Seite 7

4.2 Spare Parts List NF BN/HC 1310 D P 10 D 2.0 /-V-L24-SF50

ItemCons.

of Designation Qte. NF 1310

1. FILTER ELEMENT 1300 R 010 BN3HC /-V 1 003116721.1 Filter element 1 1300 R...1.2 O-ring 1 97,8 x 5,33

2. FILTER ELEMENT 0240 D 50 W /-V-LM246 1 012748642.1 Filter element 1 0240 D...2.2 O-ring 1 34 x 3,5

3. VR 0 A.0 1 (2) 003060063.1 Locking screw 1 VR...3.2 O-ring 1 18 x 2,5

4. VM 2 D.0 /-V-L24 1 003165564.1 Clogging indicator 1 VM...4.2 Profile sealing ring 1 VD...4.3 O-ring 1 15 x 1,5

5. SEAL KIT-E NF..1310 F 1.0 /-V-SF50 1 *)5.1 O-ring (Element 1) 1 97,8 x 5,335.2 O-ring (Element 2) 1 34 x 3,55.3 O-ring (Cover) 1 189,87 x 5,33

6. REPAIR KIT-E NF..1310 F 1.0 /-V-SF50 1 *)6.1 O-ring (Element 1) 1 97,8 x 5,336:2 O-ring (Element 2) 1 34 x 3,56.3 O-ring 3 189,87 x 5,336.4 O-ring (VR 0 A.0) 2 18 x 2,56.5 O-ring (VD 0 A.1) 1 15 x 1,56.6 Profile sealing ring (VD 0 A.1) 1 VD...6.7 Locking screw VSTI 1 G ½6.8 Locking screw VSTI 1 G ¾

*) The order number will be fixed if necessary.

NOTE:All details in this brochure are subject to technical modifications !

Electronic Pressure SwitchEDS 300

User manual

Date of issue: 08.11.2000

1. Functions of the EDS 300

Depending on the model, the unit offers the following functions:

• Display of the actual pressure, maximum value or a switching point.• Switching the switching outputs according to the pressure and the pre-set switching

parameters.• Analogue output• Menu for basic settings (adapting the EDS 300 to the particular application)• Two different types of programming enable

Four different output models are available: with one switching point, with two switching pointsand both models can also have an additional analogue output signal 4 .. 20 mA.

2. Mounting

The EDS 300 can be mounted directly onto a hydraulic block via the pressure connection(G¼ A male thread to DIN 3852). The connection adaptor ZBM 11 is available as anaccessory and is designed to ensure that the display is always visible to the user.When used in critical applications (e.g. strong vibrations or knocks) the pressure connectionmust be mechanically decoupled via a Minimess hose. Mounting clamps are available as anaccessory (see point 12.2 "Accessories - for mechanical connection").The electrical connection should be carried out by a qualified electrician according to therelevant regulations of the country concerned (VDE 0100 in Germany). The pressure switchhousing must be earthed properly at the same time. When fitted into a hydraulic block it issufficient if the block is earthed via the hydraulic system. In the case of Minimess hose-mounting, the housing must be earthed separately.Additional assembly notes which, from experience, reduce the effect of electromagneticinterference: • Make line connections as short as possible.• Use screened lines (e.g. LIYCY 4 x 0.5 mm2)• The cable screening must be fitted by qualified personnel subject to the ambient conditions

and with the aim of suppressing interference.• Direct proximity to connecting lines of user units or electrical or electronic units causing

interference must be avoided as far as possible.

3. Operating keys on the membrane keypad

3-digit

keys for setting switchingpoints,

digital display

additional functions

HYDAC EDS 300

SP1 SP2

mode

points, switch-back points and

4. Digital display

After switching on the supply voltage, the unit briefly displays “EdS” and then displays theactual pressure.

2 s

In the basic settings the display can be altered. For example, the maximum value can bepermanently displayed. This is the largest measured value which has been recorded sincethe unit was switched on or was last re-set. A switching point can likewise be permanentlydisplayed or the display can be set to be dark. Depending on the setting, "TOP", "S.P. 1","S.P. 2" or "OFF" appears briefly on the display following the switch-on message.The actual pressure can be displayed briefly by pressing the or the key. This causesthe maximum value to be re-set.

Notes: • If the actual pressure exceeds the nominal pressure of the unit, it can no longer be

displayed and the display begins to flash.• If the actual pressure is below 1 % of the nominal range, then 0 is displayed.

5. Output function

5.1 Switching outputs

The EDS 300 has 1 or 2 switching outputs. The following settings can be made under thebasic setting:

5.1.1 Switching point setting (SP)

One switching point and one hysteresis can be set for each switching output. The respectiveoutput switches when the pre-set switching point is reached and switches back when thepressure falls below the switch-back point. The switch-back point is determined by the pre-set hysteresis (switch-back point = switching point minus hysteresis).

Abbreviations: "S.P.1", "S.P.2" = switching point 1 or 2"h.Y.1", "h.Y.2" = hysteresis 1 or 2

5.1.2 Window function setting (WIN)

The window function enables a range to be monitored. For each switching output, in eachcase an upper and a lower switching value can be input which determine the range.The respective output switches when the pressure enters this range. Upon leaving the range,i.e. when the switch-back value has been reached, the output switches back. The lowerswitch-back value is just below the lower switching value (lower switching value minus threetimes the increment, see point 5.4). The upper switch-back value is just above the upperswitching value (upper switching value plus three times the increment, see point 5.4). Thearea between switching and switch-back value forms a safety zone which prevents unwantedswitching operations from occurring (e.g. triggered by pulsations from a pump).

Example for switching output 1 (normally open function):

Abbreviations: "hi.1", "hi.2" = High level 1 or 2 = upper switching value 1 or 2"Lo.1", "Lo.2" = Low level 1 or 2 = lower switching value 1 or 2

Note: The window function only operates correctly (switching on and off), when all switchingvalues (including the safety zone) are greater than 0 bar and lower than the nominalpressure range.

5.2 Analogue output

Depending on the model, the EDS 300 has one analogue output with a 4...20 mA signal.

Lo.1

hi.1 plus 3xincrement

Lo.1 minus 3xincrement

P

t

Safety zone

Safety zone

On

Off

Off

On

ON

Off

Switch-back valuetSwitching value

Switch-back valueSwitching value

hi.1

5.3. Setting the switching points, hystereses and/or critical values for the windowfunction

• Press "mode" key• "S.P.1" or "hi.1" is displayed• Keep pressing the "mode" key until the required parameter is displayed (depending on the

basic setting: "S.P.1", "h.Y.1", "S.P.2", "h.Y.2", "hi.1", "Lo.1", "hi.2" or "Lo.2").• After 2 seconds the actual setting flashes.• Use the or the keys to alter the setting.• Use the "mode" key to call up other parameters, if required, and alter the setting using the

and the keys.• If no keys are pressed for 3 seconds, the display changes back and the settings are

saved.

mode

2 s 3 s

pressuredisplay

press “mode” key until display set switching point

H

the requiredparameter is reached.

mode

G=smaller value=larger value

Notes:

• If "LOC" appears in the display when trying to alter the settings, programming is disabled.Corrective action: set programming enable to "ON"(see point 7 "Programming enable")

• If the or the key is held down during alteration, the value automatically advances.• If a setting has been altered, "PRG" appears briefly in the display when the display is

switched over. The new setting is then saved in the unit.

5.4 Setting ranges of the switching points, hystereses and/or critical values

Measuring range in bar

Switching pointand/or uppercritical value

in bar

Hysteresis and/orlower critical value

in bar

Increment *in bar

16 0.3 .. 16 0.1 .. 15.8 0.1 40 0.6 .. 40 0.2 .. 39.6 0.2100 1.5 .. 100 0.5 .. 99.0 0.5250 3.0 .. 250 1.0 .. 248 1.0400 6.0 .. 400 2.0 .. 396 2.0600 15.0 .. 600 5.0 .. 590 5.0

* All ranges given in the table are adjustable by the increments shown.

6. Basic settings

In order to adapt the unit to a particular application, the function of the EDS 300 can be alteredvia several basic settings. These are combined in a menu.

6.1 Altering the basic settings

Important note: when the menu is activated no switching operations are carried out.

Switch off supply voltage or disconnect the unit from the supply voltage.

3 s

display (release “mode” key)

mode H

press “mode” key and hold down. Switch on supply voltage

(hold key down for 3s)

mode H

mode

G 2 s

Use or to alter setting, then select next menu point.

press “mode” key until the required menu point appears in the display. (for summary, see 6.2)

To close the basic setting menu

Call up the menu point "END", set to "YES", the EDS 300 returns to the normal displaymode after 2 seconds.

Note:• If after about 50 seconds no keys have been pressed, the menu automatically closes

down. Any changes which may have been made will not be saved.

6.2 Summary of the basic settings

Setting Display Settingrange

Pre-setting

Switching mode switching output 1 (Sm 1)

Switching output 1 operates in switching point / hysteresis function

Switching output 1 operates in window function

SP/ Win SP

Switching direction switching output 1 (S 1)

“ON”: normally open function.“OFF”: normally closed function.

ON/ OFF ON

Switch-on delay switching output 1 (Ton 1)

Time in seconds which must elapse, once theparticular switching point has been reached orexceeded, before switching will occur.

0.00..75s 0

Switch-off delay switching output 1 (Toff 1)

Time in seconds which must elapse, once thepressure has fallen below the particular switch-backpoint, before switching will occur.

0.00..75s 0

Switching output 2, as above

Primary display (Primary)Display value which should remain permanently in thedisplay:

“ACT.”: base pressure“Top”: pressure peak value“S.P.1” or “S.P.2”:switching point 1 or 2“OFF”: display dark(for function, see point 4 “Digital display”)

ACT/Top/S.P.1/S.P.2/OFF

ACT

Calibration of sensor zero point (Calibrate)

“YES”: The base pressure is saved as the new zeropoint. This is possible in the range +/- 3 % ofthe unit’s nominal pressure range.

“new” appears in the display when a calibrationis carried out in the permissible range,otherwise “Err” is displayed.

This function is useful for example if there is always aresidual pressure in the system which should howeverbe displayed as 0 bar.

Please note:Following a zero point adjustment, for example, on a600 bar unit, a pressure of up to 18 bar is displayed as0 bar. Before any work is carried out on the hydraulicsystem, ensure that the system is de-pressurised.

YES/ NO NO

Version number (Version)

Display of the current software version (for referenceonly)

To close basic settings (End) YES/ NO NO

7. Programming enable

The unit has 2 types of programming enable which must both be set to "ON" to change thesettings. The operating programming enable can be set or removed during operation. Itprovides protection from unintentional alteration. A programming disable via the mainprogramming enable has the effect that no change to the settings can be carried out duringoperation. This serves, for example, as a safety function or as protection againstunauthorised alterations.

7.1 Altering the operating programming enable

mode mode

G 3 s

pressure

3 s

press both arrowkeys simultaneouslyand hold down for 3 s

use or to alter setting,

OFFON

= programming disabled= programming possible

G Gdisplay(release arrow keys)

display

7.2 Altering the main programming enable

Switch off supply voltage or disconnect the unit from the supply voltage.

mode mode

G 3 s

pressure

3 s

displaypress both arrow keys simultaneouslyand hold down.

use or to alter setting,

OFFON

= programming disabled= programming possible

G G(release arrow keys)

Switch on supply

down for 3 s)voltage (hold keys

"main program state" display

Note:

• If a setting has been changed "PRG" is displayed briefly when the display is switchedover. The new setting is then saved in the unit.

8. Error messages

If an error is detected, then a corresponding error message appears which must beacknowledged by pressing any key. Possible error messages are as follows:

E.01 The switching points and hystereses have been set in such a way that the resultingswitch-back point is no longer within the permissible setting range.

Example:Switching point is set to 180 bar, the hysteresis to 200 bar.

The setting is not correct since the resulting switch-back point is smaller than theswitching point: the error message is displayed.

Corrective action: Correct the settings

E.10 A data error has been detected in the saved settings. Possible causes are strongelectromagnetic interference or a component fault.

Corrective action: Check all the settings (programming enable, switching points, switch-back points and basic settings) and correct these if necessary. If the errors occur frequently, please contact Hydac

Service.

E.12 An error has been detected in the stored calibration data. Possible causes arestrong electromagnetic interference or a component fault.

Corrective action: Switch the unit off and on again. If the error message is stilldisplayed, the unit must be returned to the manufacturer for re-calibration or repair.

E.20 A short-circuit has been detected on a switching output.

Corrective action: Eliminate the short circuit.

9. Technical specifications

Input data:Measuring ranges: 16, 40, 100, 250, 400, 600 barOverload pressures: 32, 80, 200, 500, 800, 900 barBurst pressure: 300 % FSOutput data:Accuracy (display, analogue output) ≤ ±1.0 % FS max.Repeatability: ≤ ±0.5 % FS max.Temperature drift: ≤ ±0.3 % / 10 K zero point max.

≤ ±0.3 % / 10 K range max.Analogue output: 4 .. 20 mA, ohmic resistance ≤ 400 ΩSwitching outputs:Type: PNP transistor outputSwitching current: max. 1.2 ASwitching cycles: ≥ 100 millionReaction time: approx. 10 msAmbient conditions:Temperature range of medium: -25 .. + 80 °CAmbient temperature range: -25 .. + 80 °CStorage temperature range: -40 .. + 80 °CNominal temperature range: -10 .. + 70 °C

- mark: EN 50081-1, EN 50081-2, EN 50082-1, EN50082-2

Vibration resistance: approx. 10 g / 0..500 HzShock resistance: approx. 50 g / 1msOther data:Supply voltage: 20 .. 32 VDCCurrent consumption: approx. 100 mA (no switching output)Safety type: IP 65Hydraulic connection: G¼ A DIN 3852

torque rating 17 .. 20 NmParts in contact with medium: stainless steel, seal: FPMMaterial of housing: tube: stainless steel

keypad housing: PA6.6 Gf30Display: 3-digit, 7-segment LED, red,

height of digits 9.2 mmWeight: approx. 300 g

Note: FS (Full Scale) = relative to the full measuring range

10. Circuit diagram

Model with 1 switching output Model with 1 switching output and 1 analogue output

Plug to DIN 43650, 3 pole + earth 4 pole Binder plug, series 714 M18

4 pole plug, M12x1 4 pole plug, M12x1

Model with 2 switching outputs Model with switching outputs and 1 analogue output

4 pole Binder plug, series 714 M18 5 pole plug, M12x1

4 pole plug, M12x1

Imax. 1.2 AEDS 345-11

2

3

+

-

20..32 VSP 1

Imax. 1.2 AEDS 346-11

3

4

+

-

20..32 VSP 1

Imax. 1.2 A

EDS 346-31

3

4+

-

20..32 V

2

SP 1

RL

I = 4..20 mA

analogue

Imax. 1.2 A

EDS 344-21

2

3+

-

20..32 V

4Imax. 1.2 A

SP 1

SP 2

Imax. 1.2 A

EDS 344-31

2

3+

-

20..32 V

4

SP 1

RL

I = 4..20 mA

analogue

Imax. 1.2 A

EDS 346-21

3

4+

-

20..32 V

2Imax. 1.2 A

SP 1

SP 2

Imax. 1.2 A

Imax. 1.2 ASP 1

SP 2

EDS 348-51

3

4+

-

20..32 V 5

2 I = 4..20 mAanalogue

RL

11. Model code

Series no..(determined by manufacturer)

Type of connection, mechanical4 = G¼ A male thread

Type of connection, electrical

EDS 3 4 X - X - X 0XX - 00

4 = 4 pole Binder plug, series 714 M18

Pressure ranges in bar016, 040, 100, 250, 400, 600

Modification number000 = standard ( )determined by manufacturer

(plug not included) only available for output models " 2 " und " 3 "

5 = plug to DIN 43650, 3 pole + earth

(ZBE 01 plug included) only available for output model " 1 "

Output1 = 1 switching output

2 = 2 switching outputs (only in conjunction with electrical connection type " 5 " oder " 6 " )

( " 4 " oder " 6 " )only in conjunction with electrical connection type3 = 1 switching output and 1 analogue output

( " 4 " oder " 6 " )only in conjunction with electrical connection type

6 = 4 pole plug M12x1

(plug not included) " 1 ", " 2 " und " 3 "only available for output models

8 = 5 pole plug, M12x1, 5-pol.

(plug not included) " 5 "only available for output model

5 = 2 switching outputs and 1 analogue output ( " 8 " )only in conjunction with electrical connection type

12. Accessories

12.1 For electrical connection

ZBE 01 Right-angled plug (3 pole + earth), ZBE 02 4 pole straight Binder plug,to DIN 43650 series 714 M18

ZBE 03 Right-angled, 4 pole Binder plug, ZBE 06 and ZBE 08series 714 M18 Right-angled 4 pole plug, M12x1

ZBE 06-02 Right-angled plug (4 pole, M12x1) ZBE 08-02 Right-angled plug (5 pole, with 2 m lead M12x1) with 2 m leadZBE 06-05 Right-angled plug (4 pole, M12x1) ZBE 08-05 Right-angled plug (5 pole, with 5 m lead M12x1) with 5 m lead

12.2 For mechanical connection

ZBM 11 connection adaptor G¼ female thread - G¼A male thread for optimum alignment of the pressure switch

Colour code:

Pin 1: brownPin 2: whitePin 3: bluePin 4: black

Colour code:

Pin 1: brownPin 2: whitePin 3: bluePin 4: blackPin 5: grey

ZBM 300 clamp for wall-mounting the EDS 300 (material: polypropylene)

Mounting:

• Glue damping strips into the recesses ofthe base plate.

• Mount base plate, the top is indicated by"OBEN", "TOP" and 2 arrows.

• Insert EDS 300.• Fit clip (only one possible position) and

press hard on the cross-pieces until theyengage.

ZBM 310 clamp for wall-mounting the EDS 300 (material: polypropylene, aluminium AlSi12, steel)

Mounting:

• Weld the steel base plate• Mount EDS 300 in accordance with the

drawing

13. Dimensions

E-MOTOR 575-60

RAL 5018

..

...

...

...

11.1 Massari

......

...So 44

3076727OK-EL10L/2.0/575-60...

..

..

..

..

..

..

..

..

..

..

..

..

..

..

..

....

..

..

..

LKH

Form und Lage Genauigkeitsgradangeben! Wenn nicht gilt "H"

1:10a 19.1.01 ma/GZ 010119

.. .. .. ..

.. .. .. ..

.. .. .. ..

.. .. .. ..

.. GZ

.. ..

.. .. .. .... .. .. .. .. ..

0,5

0,05 0,1 0,2 0,4 0,8 1,6 3,2 6,3 12,5

0,25

Ra

6332168421Rz

N10N9N8N7N6N5N4N3N2Ým

Rauheitsklasse DIN ISO 1302

FertigmaìeNr.Teile-stoffWerk-NameTag

Norm.

Gepr.

Gez.

2001

0,5

ISO 2768

±0,81000

400

±0,5400120

±0,3120

30

±0,230

6

±0,16bis

ëber

AbmaìePaìmaPaìeGenauigkeitsgrad "m"

Fasen, WinkelRundungshalbmesserLçngenmaLìe

Allgemeintoleranzen +-Werkstëckkanten DIN 6784

.. ..

Ers. fër:

Ers. durch:

Teile-Code-Nr.Au

ftrag-N

r.

aus Blatt Blatt:

Benennung

Zeichnung besteht

Maìstab Masse

kgIndex Datum Name à.M.Nr.

Modell-Nr.

Schu

tzverm

erk na

ch D

IN 34

beac

hten !

Comp

uterer

stellte

Zeich

nung

(CAD

)

230

1160 ±3

1070 ±312

2

30304

700 ±2

760 ±

3

1005

±5

979

±3

700 ±15

A

G 3/4"2x

SAE 2"2x

4

M10(4x)

Dett.A 1:2.5

r10i3097

rual-

BETRIEBSANLEITUNGSERVICING INSTRUCTIONS ÖL–LUFT KÜHLAGGREGATE

OIL-AIR COOLERS UNITS

COOLING SYSTEMSVia Industria – 6814 Lamone, SwitzerlandINTERNET : http ://www.hydac.chtel. : 091 / 611 17 30fax : 091 / 611 17 39

COOLING SYSTEMS

OKA-R

OK-EL

SCA

OIL/AIR COOLER UNITS

OPERATING AND MAINTENANCE INSTRUCTIONS

TYPES AND CONSTRUCTION:Fehler! Verweisquelle konnte nicht gefunden werden.

INSTALLATIONThe mounting position of every cooler is optional. In all cases, unrestricted air flow should be ensured. The idealdistance on the suction and pressure side is described in the Oil-cooler catalogue. The inlet and outlet of the hydraulicconnection are labelled. The coolers must only be connected using hydraulic threaded connections. The hydraulicconnection on the heat exchanger should be dry and the nut should only be tightened by means of two spanner. Forsome small cooler elements the highest permissible torque rating on the threaded connections is given on the nameplate on the cooler (see dia.1).Coolers with feed pump:The maximum suction pressure is 0,4 bar. The pipe or hose on the suction side should have the following minimumcross-section: OKA-R1,2 max. flow 12 l/min, min inside diameter 19 mm; SCA1,2 max. flow 15 l/min, min insidediameter 25 mm; OKA-R3,4-EL4,5,6-SCA2,3 max. flow 60 l/min, min inside diameter 35mm; OKA-EL8,9,10,11 max.flow 180l/min, min inside diameter 55 mm.If the cooler is situated more than 4m away from the tank, or the difference in height between the cooler and the tank ismore than 2m, the cross-section should be correspondingly larger. The maximum permissible viscosity is 180mm2/sec(COLD START).A wrong rotation may damage the pump ! Verify always the direction of the pump. PLEASE NOTE: UNITS WITH FEEDPUMP MUST NEVER RUN WITH CONNECTIONS CLOSED. However, a short dry run with open connections (in orderto check the direction of rotation) does not do any damage.Coolers with hydraulic motor:The direction of rotation of the fan must be the same as that of the hydraulic motor. The direction is given on thecorresponding sticky label (see dia.2). The hydraulic motor reversible is equipped with a tank line. This line must beconnected to the tank.

WORKING PRESSUREOn units with a feed pump the maximum working pressure of 6 bar must not be exceeded. On units without a feed pumpthe maximal working pressure is 15 bar. A by-pass valve can be fitted as an optional extra to protect the unit againstpressure peaks.

ELECTRICAL CONNECTIONOil coolers with electric motors (three phase to IP55) have a terminal block connection, to VDE (or prevalent countryregulations). PLEASE ENSURE CORRECT VOLTAGE AND FREQUENCY. The direction of rotation is given on thecorresponding sticky label (see dia.2).

CONTROLSimple temperature control can be achieved using the optional thermostat. The thermostat can be built into the unit orfitted to the tank

COMMISSIONINGCheck for correct direction of rotation of the fan as given on the corresponding sticky label (see dia.2), as well as thecorrect connection and the free flow of the oil.

MAINTENANCEThe HYDAC coolers units are virtually maintenance-free. A very dusty environment might necessitate periodic cleaningof the heat exchanger. Cleaning should only be done using a soft brush to avoid damaging the fins of the element whichcould reduce the performance of the unit. On OKAF coolers (which are fitted with a filter) the contamination level of thefilter element has to be monitored. For highly contaminated air an optional air filter mat can be fitted to the suction sideof the fan.

CLEANING AND CHANGING OF THE FILTER ELEMENTUnscrew the filter housing and remove the contamination retainer together with the filter element. Dispose of dirtyresidues into a USED OIL CONTAINER. Remove the element from the contamination retainer and clean the latter.Return the contamination retainer with the new element fitted.

QUALITY TEST REPORTSAll HYDAC cooler units are subjected to a final quality test. A test report is compiled which documents the followingtests: function test, leaking-tightness of the cooler element (pneumatic or hydraulic test), noise level (only if it deviatesfrom the standard), double-check of customer’s order details. This internal document is available on request.

IK.20.E6.03Januar 1997

Pressure and Temperature Controls

Datenblatt

Pressostate und Thermostate

Typ KPS

Datenblatt

2 IK.20.E6.03

Übersicht

ISO 9001Qualitätszulassung

Übersicht über KPS Pressostate

Bereich Weitere-1 0 10 20 30 40 50 60 bar P

eTyp Informationen

bar Seite

0 - 2.5 KPS 31 3

0 - 3.5 KPS 33 3

0 - 8 KPS 35 3

6 - 18 KPS 37 3

10 - 35 KPS 39 3

Bereich Weitere-1 0 10 20 30 40 50 60 bar Pe Typ Informationen

bar Seite

2.Pressostate Typ KPS für hohe Drücke und stark pulsierende Medien

1 - 10 KPS 43 3

4 - 40 KPS 45 3

6 - 60 KPS 47 3

Übersicht über KPS ThermostateBereich Weitere

-50 0 50 100 150 200 250 °C °C Typ InformationenSeite

-10 - +30 KPS 76 8

20 - 60 KPS 77 8

50 - 100 KPS 79 8

70 - 120 KPS 80 8

60 - 150 KPS 81 8

100 - 200 KPS 83 8

Danfoss A/S hat die Zulassung von BSI nachder internationalen Norm ISO 9001. Damiterfüllt Danfoss die Forderungen derinternationalen Norm in bezug auf Produkt-entwicklung, Konstruktion, Produktion undVertrieb. BSI kontrolliert regelmäßig, obDanfoss die Forderungen der Norm einhält.Gleichzeitig kontrolliert BSI auch laufend dasDanfoss-eigene Qualitätssystem.

Pressostate und Thermostate, Typ KPS

1. Standardpressostate

Datenblatt

IK.20.E6.03 3

KPS-Pressostate sind druckgesteuerteWechselschalter, deren Kontaktstellung vomDruck am Eintrittsstutzen und demeingestellten Skalenwert abhängt. Die inkompakter Bauweise konzipierten und dichtgekapselten Geräte sind robust, stoß- underschütterungssicher und sie genügen

Einführung

1. Pressostate

*Effektiver Druck (Überdruck)

TerminologieBereichseinstellungDruckbereich, in dem das Gerät ein Signalabgeben kann (Kontaktwechsel).

DifferenzUnterschied zwischen dem Schließ- und demÖffnungsdruck (siehe auch Abb. 8 Seite 7).

Zulässiger ÜberdruckHöchster andauernder oder häufig wiederkehrenderDruck, dem das Gerät ausgesetzt werden darf.

Max. PrüfdruckHöchster Druck, dem das Gerät bei der Inbetrieb-setzung des betreffenden Systems z.B. inVerbindung mit einer Dichtheitsprüfung ausgesetztwerden darf. Es darf sich somit nicht um einenwiederkehrenden Systemdruck handeln.

Min. BerstdruckDruck, bei dem die Dichtheit des druck-empfindlichen Elements gewährleistet ist.KPS 43, 45, 47

KPS 31, 33

KPS 35, 37, 39

Bei Bestellung bitte Typ undBestellnummer angeben

Technische Daten und Bestellung

Regel- Einstellbare Zulässigerbereich bzw. feste Betriebs- Max. Druck- Bestell-Nr. Typ(pe)*) Differential druck PB Prüfdruck anschluß[bar] [bar] [bar] [bar]

0 → 2.5 0.1 6 6 G 1/4 060-3110 KPS 31

0 → 2.5 0.1 6 6 G 3/8 A 060-3109 KPS 31

0 → 3.5 0.2 10 10 G 1/4 060-3104 KPS 33

0 → 3.5 0.2 10 10 G 3/8 A 060-3103 KPS 33

0 → 8 0.4 - 1.5 12 12 G 1/4 060-3105 KPS 35

0 → 8 0.4 - 1.5 12 12 G 3/8 A 060-3100 KPS 35

0 → 8 0.4 12 12 G 1/4 060-3108 KPS 35

6 → 18 0.85 - 2.5 22 27 G 1/4 060-3106 KPS 37

6 → 18 0.85 - 2.5 22 27 G 3/8 A 060-3101 KPS 37

10 → 35 2.0 - 6 45 53 G 1/4 060-3107 KPS 39

10 → 35 2.0 - 6 45 53 G 3/8 A 060-3102 KPS 39

2. Pressostate für hohe Drücke und stark pulsierende MedienRegel- Einstellbarebereich Diff. (siehe auch

Zulässiger

Max. Max. Druck-

(pe)*) Abb. 1, 2 und 3)

Überdruck Prüfdruck Berstdruck anschluß Bestell-Nr. Typ

[bar] [bar] [bar] [bar] [bar]

1 → 10 0.7 - 2.8 120 180 240 G 1/4 060-3120 KPS 43

4 → 40 2.2 - 11 120 180 240 G 1/4 060-3121 KPS 45

6 → 60 3.5 - 17 120 180 240 G 1/4 060-3122 KPS 47

A: BereichseinstellungB: DifferenzskalaC: Erreichte Differenz

Abb. 1 Abb. 2 Abb. 3

Pressostate, Typ KPS

sowohl bei einer Innen- als Außenmontagehohen Ansprüchen.Die Pressostate werden für Regel-, Warn-und Überwachungsaufgaben an Diesel-aggregaten, Kompressoren, Kraftwerkenund Schiffen eingesetzt.

Datenblatt

4 IK.20.E6.03

KontaktsystemEinpoliger Wechselkontakt (SPDT):Kontaktmaterial: Silber, goldbeschichtet.

Kontaktlast1. Wechselstrom:Ohmsche Last 10 A, 440 V, AC-1Induktive Last 6 A, 440 V, AC-3

4 A, 440 V, AC-15Startstrom max. 50 A (blockierter Läufer).

2. Gleichstrom: 12 W, 220 V, DC-13Siehe Kurve Abb. 4.

Abb. 4. d.c.-BelastungKurve A zeigt die maximale Belastung.Die schraffierte Fläche B: ZulässigeBelastung des Goldbelags der Kontakte.

Medienberührte WerkstoffeWellrohrkapsel: Tiefziehblech, Material-Nr. 1.0524 (DIN 1624)

KPS 31, 33 Wellrohr: Rostfreier Stahl, Material-Nr. 1.4306 (DIN 17440)Druckstutzen: Druck-Stahl C20, Material-Nr. 1.0402 (DIN 1652)

KPS 35, 37,39Wellrohr: Rostfreier Stahl, Material-Nr. 1.4306 (DIN 17440)Druckstutzen: Messing W.Nr. 2.0401 (DIN 17660)

KPS 43, 45, 47 Membrankapsel: Vernickeltes Messing DIN 50 968 Cu/Ni 5 (DIN 1756)Membrane: Nitril-Butadien-Gummi.

UmgebungstemperaturKPS 31 - 39: –40 bis +70 °CKPS 43 - 47: –25 bis +70 °C

MedientemperaturKPS 31 - 39: –40 bis +100 °CKPS 43 - 47: –25 bis +100 °CFür Wasser und Seewasser jedoch max. 80 °C

ErschütterungssicherheitVibrationsfestigkeit im Bereich 2-30 HzAmplitude 1,1 mm und 30-300 Hz, 4 G.

SchutzartIP 67 gemäß IEC 529 und DIN 40050.Pressostatgehäuse aus lackiertemAluminiumdruckguß (GD-AISi 12). Deckelmit vier Schrauben befestigt. Bei einerDemontage ist der Deckel durch eineSchlaufe gesichert. Die Kapselung kann mitSicherungsdraht plombiert werden.

KabeleingangPg 13,5 für Kabeldurchmesser von5 bis 14 mm.

IdentifikationDie jeweilige Typenbezeichnung undBestellnummer ist seitlich am Geräteingeprägt.

SkalengenauigkeitKPS 31: ±0.2 bar KPS 39: ±3.0 bar

KPS 33: ±0.3 bar KPS 43: ±1.0 bar

KPS 35: ±0.5 bar KPS 45: ±4.0 bar

KPS 37: ±1.0 bar KPS 47: ±6.0 bar

Schaltpunktvariation nach 400.000Schaltungen (Mittelwerte)KPS 31: ±0.1 bar KPS 39: ±0.7 bar

KPS 33: ±0.2 bar KPS 43: ±0.2 bar

KPS 35: ±0.3 bar KPS 45: ±1.0 bar

KPS 37: ±0.4 bar KPS 47: ±1.5 bar


Zulassungen

Det norske Veritas, NorwegenAmerican Bureau of ShippingLloyds Register of Shipping, England

F Germanischer Lloyd, BRDBureau Veritas, FrankreichUmfaßt Thermostate und Pressostatemit festem Fühler und Thermostate mitarmierten Kapillarrohr.

EN 60 947-4-1EN 60 947-5-1

U Underwriters Laboratories Inc., USA

Schiffszulassungen Registro Italiano Navale, ItalienP Polski Rejestr Statków, Polen

MRS Maritime Register of Shipping,RußlandNippon Kaiji Kyokai, Japan

Datenblatt

IK.20.E6.03 5

Zubehör

Gewicht:KPS 31 - 39 ca. 1,0 kgKPS 43 - 47 ca. 1,3 kg

Maßbilder und Gewichte


Teil Beschreibung Bestell-Nr.

G 3/8 Überwurfmutter, Nippel und

Überwurfmutter mit Nippel Dichtung (10 mm außen) zum 993N3572Anlöten

G 3/8 Überwurfmutter, Nippel undDichtung (10 mm außen/6.5 mm

Überwurfmutter mit Nippelinnen) zum anschweißen 017-4229

Reduzierstück G 3/8 X 7/16 - 20 UNF (1/4 flare)Reduzierstück mit Dichtung 017-4205

Muffe G 3/8 x 1/8 - 27 NPT innen mit Dichtung 060-3334

Muffe R 3/8 außen x 7/16 - 20 UNF (1/

4 flare) 060-3240

Nippel G 3/8 A x 1/4 NPT mit Dichtung 060-3335

Nippel G 3/8 x 1/

4 - 18 NPT innen mit Dichtung 060-3336

G 1/4 A x G 3/

8 A 060-3332

NippelG 1/

4 A x M10 außen x 1 mit Dichtung 060-3338

Dämpfschleife mit 1/4 Bördel Überwurf-mutter und 1 m Kupferkapillarrohr. Wirddie Dämpfschleife in Verbindung mit Ge-

Dämpfschleife räten mit 3/8 RG Anschlüssen verwendet, 060-0071ist außerdem ein Reduzierstück, Bestell-nummer 993N3551, erforderlich.Informationen bezüglich der Länge desKapillarrohrs bei Danfoss erhältlich.

Dämpfschleife Dämpfschleife mit Überwurfmutter G 3/8

und 1,5 m Kupferkapillarrohr 060-1047

Dämpfschleife mit Überwurfmutter G 3/8

Dämpfschleife armiert 1 m armiertes Kupfer-Kapillarrohr. 060-3333 Standarddichtung wird mitgeliefert

Datenblatt

6 IK.20.E6.03

Montageverhältnisse EinstellungDeckel entfernen, Sperrschraube 5 (Abb. 6)lösen und darauf mit Hilfe der Spindel 1 untergleichzeitigem Ablesen der Skala 2 denBereich einstellen. Bei Geräten mit einstell-barer Differenz erfolgt die Differenzeinstellungmit der Spindel 3. Die erreichte Differenz kannentweder direkt auf der Skala 4 abgelesenoder – soweit es die Typen KPS 43, 45, 47betrifft – durch Ablesen des Skalenwerts undBenutzung von Nomogrammen, Abb. 1, 2, 3(Seite 3) bestimmt werden. Die Linie zurBestimmung der Differenz darf in den Nomo-grammen die dunklen Felder nicht passieren.

Abb. 6

Wahl der DifferenzUm einen zweckmäßigen automatischenBetrieb einer Anlage zu erreichen ist eineangemessene Differenz erforderlich. Bei einerzu kleinen Differenz ergeben sich kurzeBetriebszeiten mit dem Risiko der Pendelung,wogegen bei einer zu großen Differenzerhebliche Druckschwankungen auftreten.

Elektrischer AnschlußDie KPS-Pressostate sind mit einer Kabel-verschraubung Pg 13,5 ausgerüstet, die fürKabeldurchmesser von 5 bis 14 mmverwendbar ist. Gemäß den Zulassungs-bedingungen des GL ist jedoch eine spezielleSchiffskabelverschraubung vorgeschrieben.Die Kontaktfunktion geht aus Abb. 7 hervor.

Abb. 5


MontageKPS-Pressostate sind mit einer 3 mm starkenBefestigungskonsole ausgerüstet. DieGeräte sollten niemals “selbsttragend" nuram Druckstutzen befestigt montiert werden.

DruckanschlußBeim Anziehen oder Lockern der Überwurf-mutter der Druckleitung sollte immer zugleichan den Schlüsselflächen des Druckstutzensgegengehalten werden.

DampfanlagenEs empfiehlt sich, zwischen Dampfraum undPressostat eine wassergefüllte Rohrschleifevorzusehen. Diese Rohrschleife verhinderteine übermässige Erhitzung des Druck-elements. Eine solche Schleife läßt sich z.B.aus 10 mm starkem Kupferrohr herstellen(siehe Abb. 5).

Wassergefüllte AnlagenWasser im Druckelement schadet an sichnicht, jedoch besteht bei Frost die Gefahreiner Beschädigung. Um dieses Risiko aus-zuschließen, kann man für den Betrieb desGeräts ein Luftkissen vorsehen.

MedienbeständigkeitEine Übersicht über medienberührte Bauteileund Werkstoffe finden Sie auf Seite 4. Für dasMedium Meerwasser empfehlen wir die TypenKPS 43, 45, 47.

PulsationenWenn im Druckelement starke Pulsationenauftreten – z.B. in Sprinkleranlagen (Feuer-schutz), Brennstoffsystemen für Dieselmotoren(Vordruckleitung) oder in hydraulischenSystemen (Propelleranlagen) – empfiehlt sichdie Verwendung der Typen KPS 43, 45, 47.Das max. zulässige Pulsationsniveau beträgtbei diesen Typen 120 bar.

1 Bereichsspindel2 Bereichsskala3 Differenzspindel4 Differenzskala5 Sperrschraube

Abb. 7

Datenblatt

IK.20.E6.03 7


I. Ein Warnsignal für abfallenden Druck wirdbei dem eingestellten Bereichswertausgelöst.

II. Ein Warnsignal für steigenden Druck wirdbei dem eingestellten Bereichswert plusder Differenz ausgelöst.

Abb. 9

Abb. 10

Abb. 8

1. KPS 31Die Kontakte 1-2 schließen und 1-4 öffnen,wenn der Druck unter den eingestelltenBereichswert abfällt. Die Kontakte wechseln indie Ausgangslage zurück, wenn der Druckwieder auf den Bereichswert plus der Differenzsteigt (siehe Abb. 8).

Funktion

Skaleneinstellung

Mechanische Differenz

I. Ein Warnsignal für steigenden Druck wirdbei dem eingestellten Bereichswertausgelöst.

II.Ein Warnsignal für abfallenden Druck wirdbei dem eingestellten Bereichswert minusder Differenz ausgelöst.

2. Übrige KPS PressostateDie Kontakte 1-4 schließen und 1-2 öffnen,wenn der Druck den eingestellten Bereichs-wert überschreitet. Die Kontakte wechseln indie Ausgangslage zurück, wenn der Druckwieder auf den Bereichswert minus derDifferenz abfällt (siehe Abb. 9).

Skaleneinstellung

Mechanische Differenz

Beispiel 1Gewünscht wird eine Warnung, wenn in einemgegebenen Motor der Schmieröldruck unter 0,8bar zurückgeht. Die Warnung erfolgt durcheine Signallampe.Man wählt KPS 31 (Bereich 0 bis 2,5 bar). Derniedrigste zulässige Schmieröldruck von 0,8bar wird mit Hilfe der Bereichsspindel ein-gestellt. Die fest eingestellte Differenz beträgt0,1 bar. Das bedeutet, daß die Warnung solange andauert, bis der Druck auf 0,9 barsteigt. Die Signallampe wird an die Klemmen 1und 2 des Pressostats angeschlossen.

Beispiel 2Gewünscht wird eine Warnung durch einakustisches Signal (Alarmglocke), wenn ineinem gegebenen Kessel der normaleBetriebsdruck von 9 bar auf 10 bar ansteigt.Man wählt KPS 37 (Bereich 6 bis 18 bar). DerBereichswert des Pressostaten wird auf 10 bar,die Differenz auf 1 bar eingestellt.Die Alarmglocke wird an die Klemmen 1 und 4angeschloßen.

Beispiel 3In einem Startluftbehälter wünscht man, denDruck mit Hilfe eines von einem KPS

gesteuerten Kompressor so zu regeln, daßder Druck zwischen 30 und 36 bar zu liegenkommt.Man wählt KPS 45 (Bereich 4 bis 40 bar).Der Bereichswert wird auf 36 bar eingestellt.Die Differenz von 6 bar wird auf der Differenz-skala dem Nomogramm in Abb. 10entsprechend auf ca. 2 eingestelit.Die gewünschte Startfunktion ergibt sich,wenn man die Klemmen 1 und 2 miteinanderverbindet.

Datenblatt

8 IK.20.E6.03

KPS-Thermostate sind temperaturgesteuerteWechselschalter, deren Kontaktstellung vonder Fühlertemperatur und dem eingestelltenSkalenwert abhängt. Die in kompakter Bau-weise konzipierten und dicht gekapseltenGeräte sind robust,stoß- und erschütterungs-

Thermostate, Typ KPS

Einführung

Bei Bestellungen bitte Typ und Bestellnummer angeben.

KPS mit Fernfühler undarmiertem Kapillarrohr

KPS mit Fernfühler

KPS mit festem Fühler

sicher und sie genügen sowohl bei einer Innen-als Außenmontage hohen Ansprüchen. DieThermostate werden für Regel-, Warn- undOberwachungsaufgaben an Dieselaggregaten,Kompressoren, Kraftwerken und Schiffeneingesetzt.

Technische Daten undBestellung

Bestell-Nr.

Eigen- Max. Geeignete Kap.Regel- diff. Fühler- Fühlerhülsen- rohr- Typbereich einstellb./ temp. länge (siehe länge

fest auch “Zubehör“)

°C °C °C mm m

-10- 30 3-10 80 65 75 110 160 2 060L3112 060L3113 KPS 76

20- 60 3-14 130 - 75 - - - 060L3118 KPS 77

20- 60 3-14 130 - - 110 - - 060L3100 KPS 77

20- 60 3-14 130 - - 160 - 060L3136 KPS 77

20- 60 3-14 130 65 75 110 160 2 - 060L3101 060L3102 KPS 77

20- 60 3-14 130 - - 110 160 5 060L3119 060L3120 KPS 77

50-100 4-16 200 - 75 - - - 060L3121 KPS 79

50-100 4-16 200 - - 110 - 060L3103 KPS 79

50-100 4-16 200 160 060L3137 KPS 79

50-100 4-16 200 65 75 110 160 2 060L3104 060L3105 KPS 79

50-100 4-16 200 - - 110 160 5 060L3122 060L3123 KPS 79

50-100 4-16 200 - - 110 160 8 060L3124 060L3125 KPS 79

50-100 4-16 200 - 75 110 160 3 060L3143 KPS 79

50-100 9 200 - 75 - - - 060L31411) KPS 79

70-120 4.5-18 220 - 75 - - - 060L3126 KPS 80

70-120 4.5-18 220 - - 110 - - 060L3127 KPS 80

70-120 4.5-18 220 - - - 160 - 060L3138 KPS 80

70-120 4.5-18 220 - - - 200 - 060L3157 KPS 80

70-120 4.5-18 220 65 75 110 160 2 060L3128 060L3129 KPS 80

70-120 4.5-18 220 - 75 110 160 3 060L3156 KPS 80

70-120 4.5-18 220 - - 110 160 5 060L3130 060L3131 KPS 80

70-120 4.5-18 220 - - 110 160 8 060L3132 060L3133 KPS 80

60-150 5-25 250 65 75 110 160 2 060L3106 060L3107 KPS 81

60-150 5-25 250 - - 110 160 5 060L3134 060L3135 KPS 81

60-150 5-25 250 110 160 8 060L3111 KPS 81

60-150 5-25 250 200 060L3110 KPS 81

100-200 6.5-30 300 65 75 110 160 2 060L3108 060L3109 KPS 83

100-200 18 300 65 75 110 160 2 060L31391) 060L31401) KPS 83

1)Thermostat mit max. Reset

Zulassungen

Det norske Veritas, NorwegenAmerican Bureau of ShippingLloyds Register of Shipping, England

F Germanischer Lloyd, BRDBureau Veritas, FrankreichUmfaßt Thermostate und Pressostatemit festem Fühler und Thermostate mitarmierten Kapillarrohr.

EN 60 947-4-1EN 60 947-5-1

Schiffszulassungen

U Underwriters Laboratories Inc., USA

Registro Italiano Navale, ItalienP Polski Rejestr Statków, Polen

MRS Maritime Register of Shipping,RußlandNippon Kaiji Kyokai, Japan

Datenblatt

IK.20.E6.03 9


KontaktsystemEinpoliger Wechselkontakt (SPDT):goldbeschichtete Silberkontakte.Gleichstrom: 12 W, 220 V, DC-13 – SieheKurve Abb. 1.

Kontaktbelastung (Wechselstrom:)Ohmsche Last: 10 A, 440 V, AC-1Induktive Last: 16 A,440 V, AC-3

4 A, 440 V, AC-15Startstrom max. 50 A (blockierter Läufer).

Umgebungstemperatur –40 bis +70 °C

ErschütterungssicherheitVibrationsfestigkeit im Bereich 2-30 HzAmplitude 1,1 mm und 30-300 Hz, 4 G

SchutzartIP 67 gemäß IEC 529 und DIN 40050.Pressostatgehäuse aus lackiertem Aluminium-druckguß (GD-AISi 12). Deckel mit vier Schraubenbefestigt. Bei einer Demontage ist der Deckel durcheine Schlaufe gesichert. Die Kapselung kann mitSicherungsdraht plombiert werden.

Kabeleingang:Pg 13,5 für Kabeldurchmesser von 5 bis 14 mm.

IdentifikationDie jeweilige Typenbezeichnung und Bestell-nummer ist seitlich am Gerät eingeprägt.

Skalengenauigkeit KPS 76: ±3 °C KPS 80: ±3 °C

KPS 77: ±3 °C KPS 81: ±6 °C

KPS 79: ±3 °C KPS 83: ±6 °C

Schaltpunktvariationen nach 400.000 Schal-tungen: KPS 76 - 83: Abweichung max. 2 °C.

Zubehör: Fühlerhülsen für Fühler- A Gewinde Best. Nr. Fuhler- A Gewinde Best. Nr.KPS-Thermostate hülsen mm B hülsen mm B

Messing 65 1/2 NPT 060L3265

75 1/2 NPT 060L3264 Stahl 18/8 75 G 1/2 A 060L326775 G 1/2 A 060L3262

Messing 75 G 3/4 A 060L326675 G 1/2 A (ISO 228/1) 060L328175 G 3/4 A (ISO 228/1) 060L3404

110 1/2 NPT 060L3270 Stahl 18/8 110 G 1/2 A 060L3268110 G 1/2 A 060L3271 110 1/2 NPT 060L3270

Messing 110 G 1/2 A (ISO 228/1) 060L3406110 G 3/4 A (ISO 228/1) 060L3403

160 G 1/2 A 060L3263 Stahl 18/8 160 G 1/2 A 060L3269Messing 160 G 1/2 A (ISO 228/1) 060L3407

160 G 3/4 A (ISO 228/1) 060L3405

200 G 1/2 A 060L3206 Stahl 18/8 200 G 1/2 A 060L3237Messing 200 G 1/2 A (ISO 228/1) 060L3408 200 G 3/4 A 060L3238

200 G 3/4 A (ISO 228/1) 060L3402

Messing 250 G 1/2 A 060L3254

Messing 330 G 1/2 A 060L3255

Messing 400 G 1/2 A 060L3256

Messing 500 G 1/2 A 060L3257

Teil Beschreibung Anzahl je Gerät Best. Nr.

Spannband Für KPS-Thermostat mit Fernfühler (L = 392 mm) X 017-4204

Für KPS-Thermostate mit Fühler in Fühlerhülse.Wärmeleit-

Zur besseren Wärmeübertragung zwischen Fühler und Hülse. Nachpaste

Anwendungsbereich für Paste: Bedarf 41E0110(Tube mit 4,5 cm3)

-20 °C bis +150 °C, kurzfristig bis 220 °C.

Wird ohne Schlitzschraube,Dichtung und Unterleg-scheiben geliefert

Abb. 1. d.c.-BelastungKurve A zeigt die maximale Belastung.Die schraffierte Fläche B: ZulässigeBelastung des Goldbelags der Kontakte.

Datenblatt

10 IK.20.E6.03


Maßbilder und Gewichte

Montage Anordnung des Geräts:Thermostate KPS können von der Konstruktionher den allgemein auftretenden Erschütte-rungen z.B. auf Schiffen, an Kompressorenoder größeren Maschinenanlagen wider-stehen. Die Montage kann entweder mit Hilfeder Konsole direkt an einer Wand, einemSchott u. dergl. (Thermostate mit Fernfühler)oder auch selbsttragend auf einer Fühlerhülse(Thermo-state mit festem Fühler) erfolgen.

MedienbeständigkeitMaterialspezifikationen für Fühlerhülsen:

Fühlerhülse aus MessingRohr aus Ms 72 gemäß DIN 17660, Gewinde-stück aus So Ms 58 Pb gemäß DIN 17661.

Fühlerhülse aus rostfreiem Stahl 18/8Materialbezeichnung 1.4305 gemäß DIN17440.

FühleranordnungDer Fühler sollte möglichst so angeordnetwerden, daß seine Längsachse rechtwinklig zurStrömungsrichtung verläuft. Der aktive Teil desFühlers beträgt bei Geräten mit angebautemFühler und mit 2 m Kapillarrohr Ø13 mm x 50mm. Bei den übrigen Thermostaten (5 m und8 m Kapillarrohr) beträgt der aktive Fühlerteil70 mm.

MedienverhaltenDie schnellste Reaktion ergibt sich bei einemMedium mit großer spezifischer Wärme undhoher Wärmeleitfähigkeit. Daher ist es – fallsman hinsichtlich der Medienwahl frei ist –vorteilhaft, ein Medium zu wählen, das dieseVoraussetzungen erfüllt. Auch ist die

Abb. 3

Strömungsgeschwindigkeit des betreffendenMediums von Bedeutung. (Die optimaleStrömungsgeschwindigkeit für Flüssigkeitenbeträgt ca. 0,3 m/s). Zulässiger Mediendruck:Siehe Abb. 2.

Abb. 2. Zulässige Mediendruckwerte gegenFühlerhülsen als Funktion der Temperatur

EinstellungGehäusedeckel entfernen, Sperrschraube 5Abb. 3 lockern und danach den Bereich durchBetätigung der Spindel 1 und Ablesen derSkala 2 einstellen.Bei Geräten mit einstellbarer Differenz wirddiese durch Betätigung der Spindel 3 undAblesen der Skala 4 eingestellt.

1. Bereichs-spindel

2. Bereichs-skala

3. Differenz-spindel

4. Differenz-skala

5. Sperr-schraube

KPS mit Fernfühler und armiertemKapillarrohrGewicht: ca 1.4 kg(mit 2 m armiertem Kapillarrohr)

KPS mit festem FühlerGewicht: ca 1.0 kg

KPS mit FemfühlerGewicht: ca 1.2 kg(mit 2 m normalem Kapillarrohr)

NichtrostenderStahl

Messing

Datenblatt

IK.20.E6.03 11


Elektrischer AnschlußKPS-Thermostate sind mit einer Pg 13,5Kabelverschraubung versehen, die für Kabel-durchmesser von 5 bis 14 mm verwendbar ist.Nach den Zulassungsbedingungen des GL istjedoch eine spezielle Schiffskabel-verschraubung vorgeschrieben. DieKontaktfunktion geht aus Abb. 5 hervor.

Abb. 4

Einstellungsbeispiele Beispiel 1Dieselmotor mit einer Kühlwassertemperaturvon 85 °C (Normalzustand). Gewünscht wirdein Warnsignal, sobald die Kühlwasser-temperatur 95 °C überschreitet. Zu wählen wäreein Thermostat KPS 80 (Bereich 70 bis 120°C)

Einstellung der Hauptspindel: 95 °CEinstellung der Differenzspindel: 5 °CDie gewünschte Warnfunktion ergibt sich, wennman die Klemmen 1-4 verbindet.

Nach einer gewissen Betriebsdauer desSystems ist zu überprüfen, inwieweit dieBetriebsdifferenz den Gegebenheitenentspricht und ob eventuell eine Korrekturvorzunehmen ist.

Beispiel 2Zu ermitteln ist die notwendige Skalenkorrekturfür einen KPS 80, der bei einer Umgebungs-temperatur von 50 °C auf 95 °C eingestellt ist.Die relative Skaleneinstellung Z wird nachfolgender Formel bestimmt:

Einstellwert – min. Skalenwert

Max. Skalenwert – min Relative Skalenwert

Relative Skaleneinstellung: 95 – 70 × 100 = 50% 120 – 70

Faktor für Skalenabweichung (gemäß Abb. 4)Z ≅ 0.7Korrekturfaktor a vgl. Tabelle unter Abb.4 = 2,4

Skalenkorrektur = Z × a = 0.7 x 2.4 = 1.7 C°KPS ist auf 95 + 1.7 = 96.7 C° einzustellen

SkalenkorrekturDie Fühler der KPS-Thermostate enthalten einesogenannte Adsorptionsfüllung und können somitohne Beeinträchtigung ihrer Funktion wärmer oderkälter als der übrige Teil des thermostatischenElements (Wellrohr und Kapillarrohr) angeordnetwerden. Eine solche Füllung ist zum TeilÄnderungen der Wellrohr- und Kapillarrohr-temperatur gegenüber empfindlich, ein Umstand,der aber unter normalen Verhältnissen ohneBedeutung ist.Wenn dagegen die Thermostate bei extremenUmgebungstemperaturen eingesetzt werden, soergeben sich Skalenabweichungen, die man wieunten angegeben ausgleichen kann:Skalenkorrektur = Z × aZ ermittelt man mit Hilfe der Abb. 4, während adie Bezeichnung des Korrekturfaktors gemäßnachstehender Tabelle ist. Siehe Beispiel.

Korrekturfaktor aRegel- für Thermostate

Typ bereich mit mit mitfestem 2 u. 5 m 8 m

°C Fühler Kap. rohr Kap. rohr

KPS 76 –10 - +30 1.1

KPS 77 20 - 60 1.0 1.4

KPS 79 50 - 100 1.5 2.2 2.9

KPS 80 70 - 120 1.7 2.4 3.1

KPS 81 60 - 150 3.7

KPS 83 100 - 200 6.2

Abb. 5

RelativeSkalen-einstel-lung in %

× 100 = %

Faktor fürSkalenabweichung

Die in Katalogen, Prospekten und anderen schriftlichen Unterlagen, wie z.B. Zeichnungen und VorschlŠgen enthaltenen Angaben und technischen Daten sind vom KŠufer vor †bernahmeund Anwendung zu prŸfen. Der KŠufer kann aus diesen Unterlagen und zusŠtzlichen Diensten keinerlei AnsprŸche gegenŸber Danfoss oder Danfoss-Mitarbeitern ableiten, es sei denn, da§diese vorsŠtzlich oder grob fahrlŠssig gehandelt haben. Danfoss behŠlt sich das Recht vor, ohne vorherige Bekanntmachung im Rahmen des Angemessenen und Zumutbaren •nderungenan ihren Produkten Ð auch an bereits in Auftrag genommenen Ð vorzunehmen. Alle in dieser Publikation enthaltenen Warenzeichen sind Eigentum der jeweiligen Firmen. Danfoss und dasDanfoss-Logo sind Warenzeichen der Danfoss A/S. Alle Rechte vorbehalten.

DanfossWŠrme- undKŠltetechnik GmbHPostfach 126163130 HeusenstammTel.: (06104) 698-0Telefax: (06104) 698-409

IK.20.E6.03 12

Wahl der DifferenzUm einen zweckmäßigen automatischenBetrieb der Anlage zu erreichen, ist eine ange-messene Differenz erforderlich. Bei einer zukleinen Differenz ergeben sich kurze Betriebs-zeiten mit dem Risiko der Pendelung, wogegenbei einer zu großen Differenz erheblicheTemperaturschwankungen auftreten.

DifferenzbegriffeAls mechanische Differenz (Eigendifferenz)bezeichnet man den an der Differenzspindeleingestellten Wert. Dagegen nennt man dieDifferenz, mit der die Anlage arbeitet, diethermische Differenz (Betriebsdifferenz).


Funktion Die thermische Differenz ist stets größer alsdie mechanische Differenz und ist von dreiFaktoren abhängig:1) Strömungsgeschwindigkeit des Mediums,2) Änderungsgeschwindigkeit der Medien-

temperatur und3) Wärmeübertragung auf den Fühler.

ThermostatfunktionDie Kontakte 1-4 schließen und 1-2 öffnen,sobald die Temperatur über den auf der Skalaeingestellten Wert (Sollwert) ansteigt. DieKontakte gehen wieder in ihre Ausgangslagezurück, wenn die Temperatur auf einen demSollwert minus der Differenz entsprechendenWert abfällt. Siehe Abb. 6.

© Danfoss A/S AG-SP. kaa 01-97

I. Ein Warnsignal für steigendeTemperatur wird beim Bereichs-einstellwert ausgelöst.

II. Ein Warnsignal für abfallendeTemperatur wird beim Bereichs-einstellwert minus der Differenzausgelöst.

Abb. 6

MechanischeDifferenz

Skaleneinstellung

Datenblatt

STÜWEReibschlußverbindungen Ausgabe

EDITIONSchw.

HSD 620-22Schrumpfscheibe

Typ HSD Baureihe 22 16.11.00

STÜWE Postfach 800557 ( (02324) *394-0GmbH & Co. KG D-45505 Hattingen Telefax (02324) 39430

HSD 620-22x620

Spannschrauben: 28x M30, DIN 933 – 10.9max. Schraubenanzugsmoment: 1.640 Nm

D = Ø 970 mml = 254 mmH = 286 mmA = Ø 706 mmd1 = Ø 630 mme = 29 mmd = 620 mm H8/f7dw = 520 mm H7/h6

Max. übertragbares Drehmoment MT = 3.169 kNm ( µw = 0,15)

H

D

Ad dw

l ed1

Mounting and Removal Instructions

for Shrink Discs

Mounting

The shrink discs are supplied ready to be installed. Therefore they should not be dismantled prior toemploying the unit for the first time.

1. Degrease shaft and hub bore.2. Push shrink disc on hub. The outer surface of the hub may be greased in the area of the shrink

disc fit.

CAUTION !

Do not tighten the tightening bolts before attaching the shaft.

3. Mount hub on the shaft.4. Tighten all tightening bolts uniformly, one by one, over several revolutions until the outer ring and

inner ring are in line and the full tightening torque is reached.

Demounting

1. Loosen all locking bolts uniformly one by one, initially not more than a quarter turn per bolt, until itis observed that the outer ring has released from the inner ring.

CAUTION !

Under no circumstances should the locking bolts be completely removed as this could bedangerous and result in injury.

2. Should the outer ring not-self release from the inner ring, this can be assisted by removing thoselocking bolts adjacent to the tapped holes provided for jacking purposes and screwing them intothese tapped holes. The jacking procedure must continue until release of the outer ring isachieved.

3. Dismount shaft or draw off hub. Remove rust which may have formed on the shaft in front of thehub.

4. Remove shrink disc from hub.

Cleaning and greasing

Dismantled shrink discs do not have to be taken apart and regreased before remounting.The shrink disc has to be cleaned and regreased only if employed in dirty environment.Use a solid lubricant with a coefficient of friction of µ = 0,04 for the conical surfaces as well as bolts.

Example:

Molykote 321 R Spray made by Corning

Aemasol MO 19 P Spray or paste made by A.C.Matthes (friction-reducing varnish)

Molykote spray Spray made by Dow Corning Molykombin

UMFT 1 Spray made by Klüber Lubric (powder-spray)

Molykote G Rapid Spray or paste made by Unimoly

P5 Powder made by Klüber Lubric Dow Corning

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