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GE Energy Products – Europe

OPERATION AND MAINTENANCE MANUAL

COMPONENT AND SYSTEM LITERATURE

EQUIPMENT DEFINITION

GE DEVICE

:

HM1

DESIGNATION

:

TORQUE CONVERTER AND REVERSING GEAR

SUPPLIER

:

VOITH

TYPE

:

EL10ZFG

LITERATURE REFERENCE

:

3626-020618 EN

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- 1 - Instruction Manual for VOITH Torque Converter Type: EL 10 ZFG Serial No.
-
1 -
Instruction Manual
for
VOITH Torque Converter
Type:
EL 10 ZFG
Serial No. :
Code:
GE France
In case of any queries with regard
to this unit we would ask you to
always state the serial no.
2002-10-21
Voith Turbo GmbH - D-74555 Crailsheim
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3626-020618 en
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Instruction Manual for VOITH Torque Converter - Contents -

   
  - 2 -
 

- 2 -

Instruction manual:

 

Data sheet

3626-020618 en

Text

3626-017476 en

Parts list

3626-017391 de/en

Longitudinal view

4 153947 0

Cross section

4 154877 0

Control valve with one limit switch

 

4 153843 0

Installation electric rotary actuator

4 156897 0

Control diagram

3623-014636

Assembly plan

3600-030905

VOITH information sheets:

 

Preservation

3625-006212

Operating fluids for VOITH Torque Converter

3625-006072

Adjustment description of the limit switch

 

3626-013514

Mounting aid

Bush ( mounting aid )

 

3623-013151

Distance ring with flange ( mounting aid )

3623-013152

Holding disc ( mounting aid )

 

3623-013154

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Instruction Manual for VOITH Torque Converter - Contents -

   
  - 3 -
 

- 3 -

Attaching parts (description):

 

Guide vane actuator VOITH - Order No:

Type: SA10.1-G0-D-90-D400/50-6-9-10-11-21.4/0-22.1-KE-21-X with three phase motor 400 V / 50 Hz

 

Operating Instructions

 

DO 01.05.001 GB / 1.00

Solenoid valve Voith - Order No. :

 

Type: WL 4 BNZ 10 X P5 EK 3 K1 110 - S1 Electrical connection: 120 VDC ± 10 %

 

Dimension sheet Description

 

3626-014390 de/en BV 2500.78 GB

Vent filter VOITH - Order No:

 

Order - Nr.: 41 002 62 102

Instruction

VKD 6723.1 0887

Limit switch VOITH - Order No:

 

Type: 3SE3 100-1B

Instruction

GWA 4NEB 330 0648-10a

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Instruction Manual for VOITH Torque Converter - Data Sheet -

   
  - 4 -
 

- 4 -

Torque Converter:

EL10 ZFG

 

Code:

GE France W 48

Voith Order No:

Serial No.:

Input shaft

Output shaft

Sense of rotation viewed in direction of the power flow:

CCW

 

CCW

Guide vane adjustment from "closed" to "open":

approx.240 turns

see assembly plan

 

Torque Converter as gas turbine drive

 

Rated power of converter:

 

P1 =1416 kW

Rated speed of converter:

n1 = 2950 RPM

Raising speed (Converter circuit must then be discharged)

n2 = 2100 RPM

Weight without oil filling:

 

approx.1075 kg

Foundation load:

see assembly plan

 

Oil supply to the torque converter:

 

oil supply system

Control valve 1, for filling and draining , with / without limit switch

 

Guide vane actuator :

Electric actuator ( technical data, please see sheet 3)

Connecting coupling:

 

Input side

output side

 

*

*

Oil cooling:

*

*) not VOITH-supply

 

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Instruction Manual for VOITH Torque Converter - Data Sheet -

   
  - 5 -
 

- 5 -

Operating data for torque converter

 

Working oil temperature in the flow to the torque converter

Nom. value

approx. 60 °C

Working oil temperature in the flow from the torque converter

Nom. value (smaller) Alarm at Shutdown at

 

90 °C

110 °C

 

120 °C

Lube oil temperature in the flow to the torque converter

Nom. value

approx. 60 °C

Lube oil temperature in the flow from the torque converter

Nom. value

approx. 80°C

Filling pressure (operating condition)

 

Nom. value

approx. 4.0 bar 2.1 bar

Alarm

Control pressure (= pressure of oil supply system)

Nom. value

approx. 7.0 bar

Torque converter pressure (operating condition)

Nom. value up to Alarm (smaller than)

12.0 - 18.0 bar 10.0 bar

Lube oil and cooling oil pressure

Nom. value

approx.1.5 bar

Required working oil flowrate (operating condition)

 

approx. 16.0 l/sec

Required lube oil and cooling oil flowrate

approx. 0.6 l/sec

Turning speed (speed at which the pony motor is switched)

from 100 to 400 rpm

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  Operating Instructions for - 1
 

Operating Instructions

for

- 1

   

-

VOITH Torque Converter EL 10 ZFG

 

CONTENTS

Safety Information

 

1. Design and Operation

1.1 Design

1.2 Operation - torque converter

 

2. Oil Circuits

 

2.1 General

 

2.2 Working oil circuit - torque converter operation

 

2.3 Control oil circuit

 

2.4 Lube and cooling oil circuit

 

3. Control Valve

 

3.1 Control

 

3.2 Adjustment

4. Guide Vane Adjustment

4.1 General

4.2 Actuator

5. Design and Delivery

6. Installation

 

6.1 General information

 

6.2 Shaft misalignment due to operation, alignment accuracy

 

6.3 Checks prior to mounting

 

6.4 Mounting the torque converter on the foundation

 

6.5 Site pipework

 

6.6 Guards

6.7 Preservation after installation

 

6.8 Electric installation

 

7. Operating Oil

 

7.1

Lubricant

 

8. Commissioning

 

8.1 Trial run preparations

 

8.2 Trial run

8.3 Steps to be taken at standstill periods and stand-by operation

 

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  Operating Instructions for  
 

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VOITH Torque Converter EL 10 ZFG

- 2 -

9. Torque Converter Operation

 

9.1 Start-up of the unit

9.2 Turning the unit via the torque converter

 

9.3 Manual emergency operation of filling and draining control

 

9.4 Unit shutdown

 

9.5 Operating data

9.6 Operating oil pressure indication

 

9.7 Operating oil pressure monitoring

9.8 Operating oil temperature indication including monitoring

 

10. Maintenance Intervals and Measures to be taken

 

10.1 Measures which can be taken when the unit is running

 

10.2 Measures which can only be taken when the unit stands still

11. Overhaul of the Voith Torque Converter

 

12. Disassembling/Reassembling the Torque Converter

12.1

General

 

12.2

Preliminary work

 

12.3

Dismantling the control housing

 

12.4

Dismantling the input and output part

12.5

Adjustment of bearing clearances and reassembly of the torque converter

 

12.6

Mounting the turbine wheel and output part

 

12.7

Mounting the control housing

12.8

Remaining work

 

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Operating Instructions for VOITH Torque Converter EL 10 ZFG - 3 - Safety Information ATTENTION

Operating Instructions

for

VOITH Torque Converter EL 10 ZFG

Instructions for VOITH Torque Converter EL 10 ZFG - 3 - Safety Information ATTENTION Dangerous voltages

- 3 -

Safety Information ATTENTION Dangerous voltages and/or high pressures and temperatures may occur in equipment,
Safety Information
ATTENTION
Dangerous voltages and/or high pressures and temperatures may occur in equipment,
subassemblies and pipework during operation of the unit. This unit and the equipment and
pipework contain among others oil as operating medium.
Improper handling may therefore cause bodily injury or damage to property. Improper
handling of oils and lubricants may pollute the environment. Filling, changing, handling and
waste disposal of oil is to be done by qualified personnel.
IMPORTANT
Only qualified personnel is allowed to operate this unit, the equipment and its
media.
A
condition for sound and safe operation of this unit is proper transportation, appropriate
storage, setup and installation, proper handling according to instructions, conscientious
use of the operating medium oil as well as careful operation and servicing.
If
you should need any further information or any particular problems should occur which
are not dealt with in detail in the manual, please contact the VOITH Subsidiaries or the
factory directly.
Qualified Personnel
are persons who are familiar with the transportation, storage, setup, installation,
commissioning, operation and maintenance of the product and qualified to do their job,
as e.g.:
-
training, instruction and entitled to operate and service the equipment, units, systems in
accordance with established safety practices for electrical circuits/wiring, high
pressures and temperatures and media harmful or detrimental to the environment
-
proper handling and disposal of media and their components, e.g. filters/one-way
systems/oils etc.
-
training or instruction according to established safety practices for maintenance and
use of safety equipment
-
training in first aid

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Operating Instructions for    

Operating Instructions

for

   

VOITH Torque Converter EL 10 ZFG

- 4 -

1.

Design and Operation

 

1.1

Design

 

The Voith torque converter is a hydrodynamic gear unit working to the Föttinger principle.

The two-stage hydrodynamic torque converter consists of the following main components:

torque converter consists of the following main components:   1. Input shaft 5. Guide wheel adjustable
 

1. Input shaft

5.

Guide wheel adjustable

2. Pump impeller

6.

Output shaft

3. Turbine wheel 1

7. Adjustment mechanism

 

4. Turbine wheel 2

8. Guide wheel fixed

 

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Operating Instructions for  

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VOITH Torque Converter EL 10 ZFG

 

- 5 -

The input shaft is connected with the pump impeller. The output shaft is connected with the turbine wheels. Both converter shafts are supported by antifriction bearings. The input shaft is sealed using a labyrinth and the output shaft using a labyrinth with felt ring.

The adjustable vanes of guide wheel are connected mechanically with the adjustment mechanism and dependent on the converter operating state they are moved to 0 % or 100 % guide vane position.

The pump impeller, the guide wheels and the turbine wheels form the oil-filled circuit together with the converter shell.

The housing of torque converter supports the internal parts controlling the oil supply and oil discharge.

A

control housing is attached to the converter housing supplying the torque

converter with operating oil.

 

A

control valve is installed in the control housing. This control valve is switched to

"fill" and "drain" the torque converter.

 

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VOITH Torque Converter EL 10 ZFG

 

- 6 -

1.2

Operation - torque converter

 

The hydrodynamic torque converter is provided for stepless speed/torque transmission (multiplication) between motor and gas turbine to be started.

The pump impeller absorbs the mechanical energy of the driving machine (motor) with the 3rd power of input speed (n 3 ) converting it to kinetic energy by accelerating the oil in the converter. The turbine wheels convert the kinetic energy existing in the fluid mass back to mechanical energy.

The guide wheels absorb the differential torque between pump impeller and turbine wheel which results in a multiplication of torque. The guide vanes of the second guide wheel are adjustable and effect a change of the flow direction. The inside diameter between the guide vanes , relative to the value in the design point, is provided as "relative guide vane position" (in %) to describe the operating behaviour.

 
   
 

Dependent on the guide vane position, between 0 % and 100 %, a corresponding torque is transmitted via the turbine wheels as a function of the output speed.

The pump and the turbine rotate in the same direction.

 

There is no mechanical connection between pump impeller, turbine wheels and guide wheels.

Torque transmission is load-dependent, i.e. the torque produced in the turbine wheels has its max. point when the output shaft stands still and decreases with increasing speed. Thus the torque converter is adapting steplessly and automatically to the resistance occurring.

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VOITH Torque Converter EL 10 ZFG

 

- 7 -

2.

Oil Circuits

 

2.1

General

 
 

The same oil is used as working, control, lube and cooling oil.

 

The torque converter is supplied with operating oil (lube and cooling oil, working and control oil) from the oil supply system via pumps operating independently of each other.

 

2.2

Working oil circuit - torque converter operation

 
 

On converter operation, the valve in the control housing is switched to "filling" via the servo valve. The pump of the oil supply system supplies the working oil to the control housing through the working oil orifice plate, via the guide vane cover directly into the torque converter working chamber. For heat dissipation, a certain quantity of working oil flows from the closed circuit of the working chamber back into the oil supply system via the set annular gap of the control valve. The filling pressure of the working oil (in the flow from the orifice plate) is set to 4 bar by the working oil orifice plate.

The converter pressure in the flow to the working oil outlet must be between 12 and 18 bar. This value is dependent on the output speed and guide vane position. Adjustment is described in par. 3 "Control Valve".

If the valve in the control housing is switched to "draining" by the servo valve, the oil supply is interrupted and the working chamber is drained quickly via large opening cross sections.

 

2.3

Control oil circuit

 
 

The piston of control valve is fed with control oil via the servo valve. The control oil pressure is approx. 7.0 bar.

 
 

2.4

Lube and cooling oil circuit

 
 

Pump 2 of the oil supply system supplies lube oil for the bearing points and cooling oil for cooling the torque converter parts during gas turbine operation.

The lube and cooling oil pressure is approx. 1.5 bar.

 

The lube, cooling and control oil accumulated in the torque converter housing is supplied back into the oil supply system via an oil return piping.

 

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Operating Instructions for - 8 - VOITH Torque Converter EL 10 ZFG 3. Control Valve

Operating Instructions

for

- 8 -

VOITH Torque Converter EL 10 ZFG

3. Control Valve

3.1 Control The control valve (for torque converter filling and draining) is switched by means
3.1
Control
The control valve (for torque converter filling and draining) is switched by means
of a servo valve (4/2 way solenoid valve).
If the limit switches are wired, the position of the control piston is indicated by an
electrical signal.
In addition, the servo valve has a manual emergency actuation. See par. 9.3.
The control valve is provided for torque converter filling or draining. By means of
the adjusting screw on this valve, the output cross section and thus the working oil
flow rate through the torque converter can be adjusted. When adjusting, please
observe the required torque converter pressure.
3.2
Adjustment
For adjusting the torque converter pressure and the working oil flow rate through
the torque converter, remove the screw plug on the valve housing (see
longitudinal section). The piston stroke and thus the cross-sectional area in the
selector valve is adjusted by removing or adding shims/washers below the
adjusting screw. Screw in the screw plug after adjustment.
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VOITH Torque Converter EL 10 ZFG

 

- 9 -

4.

Guide Vane Adjustment

 

4.1

General

 
 

The guide vane adjustment enables a continuous change of the power transmission. This means that a speed adaptation is possible for any drive of driven machine whereas the load-dependency remains unchanged.

 

4.2

Actuator

 
 

(see enclosed instruction manual for the AUMA actuator)

 

The guide vanes are adjusted via an electric motor driven actuator. This actuator directly acts on the adjusting ring of the converter via the adjusting lever. The guide vanes are turned correspondingly via this adjusting ring

 

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VOITH Torque Converter EL 10 ZFG

 

- 10 -

5.

Design and Delivery

 

Test run

Prior to delivery each torque converter has been subjected to a test run.

 

Parameters measured:

Input and output torque under test load with open or closed guide vane position, vibrations on the bearing housing, filling and draining times.

Parameters set:

Working oil quantity in the working chamber, converter pressure, max. guide vane adjustment, torque-dependent and way-dependent limit switches (on the actuator) and valve limit switches. Average cross section for working oil outlet.

Operational test:

Filling/drain valve, guide vane adjustment.

 

Preservation

The standard preservation according to Sheet 3.625-006212 provides up to 6 months protection.

As delivered condition

 

The torque converter is ready for mounting. All internal pipes are layed for the corresponding oil circuits. Indicating instruments, as far as ordered, are fitted. Pipe connections, e.g. from and to the oil supply system, are provided with flanges or caps. The working oil orifice plate is installed.

When the connecting couplings are supplied, the coupling hubs are mounted.

 

Spare parts and loose parts for the torque converter are separately packed for delivery.

Transportation

For transportation of the torque converter eyebolts are fitted on top of the housing. Regarding the transportation weight of the torque converter without oil filling and packing, please refer to the assembly drawing.

 

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VOITH Torque Converter EL 10 ZFG

 

- 11 -

6.

Installation

 

6.1

General information

 
 

The following work (para. 6.2 - 6.8) is to be carried out by qualified personnel only (see Safety Information).

We therefore suggest to have one of our specialized service engineers carry out installation and commissioning.

Faulty installation can lead to failures and early wear of the units.

 

Regarding installation dimensions etc. please refer to the outline drawing.

We recommend to paint the foundation using an oil-resistant paint, to avoid that oil gets into the foundation when wetting the foundation with oil and thus avoiding damage of the concrete.

When mounting the connecting coupling hubs please take note of the installation direction (position of gear teeth and detaching thread, etc.) and of the attachment parts behind the hub.

is only allowed to hang the torque converter on the lugs provided for this purpose (see assembly plan).

It

During the period of construction at site, cover the torque converter fully against rubbish, throwing off of sparks, grinding dust and other environmental influence detrimental to the torque converter. In particular, the monitoring instruments need

a

special protection.

 
 

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Operating Instructions for VOITH Torque Converter EL 10 ZFG - 12 - 6.2 Shaft misalignment

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VOITH Torque Converter EL 10 ZFG

Instructions for VOITH Torque Converter EL 10 ZFG - 12 - 6.2 Shaft misalignment due to

- 12 -

6.2

Shaft misalignment due to operation, alignment accuracy

6.2 Shaft misalignment due to operation, alignment accuracy
   
 

(Dimensions in mm)

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In operation the shafts of driven machine, torque converter and gear unit are to be in alignment. For alignment, please consider the shaft misalignments of the different units due to operation.

Shaft misalignments of torque converter relative to 20°C installation temperature and 80°C operating temperature.

Fixed point to the foundation

Fixed point to the foundation

40 °C)

Values starting from the fixed point A or B are equal to the max. shaft misalignment including bearing clearance.

starting from the fixed point A or B are equal to the max. shaft misalignment including

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VOITH Torque Converter EL 10 ZFG

Instructions for VOITH Torque Converter EL 10 ZFG - 13 - A proper alignment is guaranteed

- 13 -

A proper alignment is guaranteed when using 3 dial gauges for measuring axial center offset
A proper alignment is guaranteed when using 3 dial gauges for measuring axial
center offset and angular deflection and turning the shafts jointly.
Alignment accuracy under hot running conditions:
Speed
RPM
Shaft center line displacement max.
(face wobble = values doubled)
Max. angular displacement
up to 1500
0.1 mm
0.03
mm per 100 mm
test radius
above 1500
0.05 mm
0.02
mm per 100 mm
up to
3600
test radius

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VOITH Torque Converter EL 10 ZFG

 

- 14 -

After alignment of torque converter record the alignment values in 1/100 mm according to the sketch.

 

Shaft centre line displacement

Angular displacement

 
centre line displacement Angular displacement   6.3 Checks prior to mounting   Check the

6.3

Checks prior to mounting

 

Check the foundation dimensions for the torque converter and position to drive motor and gas turbine.

Check the connecting coupling hubs for the required direction of installation. Please observe the shaft clearances according to the specifications applicable to connecting couplings. Measure and record radial run out and axial clearance of the shafts of drive motor and gas turbine.

Check the clearance on the foundation for shimming and aligning the torque converter.

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VOITH Torque Converter EL 10 ZFG

 

- 15 -

6.4

Mounting the torque converter on the foundation

 

Data regarding foundation load are stated on the assembly plan.

 

Concrete foundation

 

For a concrete foundation two foundation rails or four rigid base plates with the bore-holes for the anchor bolts are required. These foundation rails or base plates are to be designed that there is sufficient space for grouting of the anchor bolts.

After assembly of the connecting couplings, the torque converter is placed on the foundation with

After assembly of the connecting couplings, the torque converter is placed on the foundation with suspended anchor bolts, 10 mm shim and foundation rails. Then align the torque converter preliminarily and provide the foundation rails or base plates with an adequate lining. Finally, grout the anchor bolts and foundation rails with concrete. After the concrete has set,align the torque converter finally using liners and shims, taking the shaft displacements of the individual units due to operation into consideration. All shims must bear weight uniformly.

After tightening up the anchor bolts measure and record the accuracy of alignment (radial and axial run-out) by rotating the shafts together (see 6.2).

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VOITH Torque Converter EL 10 ZFG

- 16 -

Steel foundation

 

Fit connecting couplings and oil drain piping then set the torque converter on the foundation.

Align as per par. 6.2. If there is a common foundation, all units must be in position on this foundation before alignment.

Important:

All shims must bear weight uniformly to prevent housing buckling when anchor bolts are tightened up. After tightening up the bolts measure and record alignment values, as described in para. 6.2.

6.5

Site pipework

 

Pipe the oil feed and oil return, leakage oil drain, lube and cooling oil at the torque converter. They must be designed with the tube diameters indicated on the drawing.

For flushing the site piping, provide detachable pipe sections on the oil inlet (in the flow to the torque converter) which are removed for flushing so that an oil filter can be installed in between.

We recommend to adapt the site piping only after alignment of the torque converter. Please take care that the pipes installed are free from stress.

Oil pipes which are laid at site are to be unscrewed after completion and to be pickled in a standing bath. Mixing proportion: 1 part BETONA to 10 parts water result in this pickling solution. Mix 1 to 3 litres pickling degreasing agent S 13 on 100 litres pickling solution to remove dirt, light fouling, graphite or oil carbon. Workpieces heavily fouled by oil or grease are to be degreased in advance. The ideal temperature of the pickling solution for pickling is approx. 40°C. Put and leave the parts in the pickling solution for the periods mentioned below.

Pickling period:

 

(splashing)

Rust film:

approx.

5 to 10 min 15 to 30 min 50 min. 120 min.

 
 

Rust:

approx.

Rolling scale: approx.

Descaling of annealed steel pieces:

approx.

Then remove the parts, do not wash them, let them dry drip-proof. Drying time to achieve an ideal protective film at 20°C is between 24 and 48 hours. If the drying time cannot be adhered to, subsequent flushing using clean water is required. Then dry the parts, spray them on the inside with working oil and on the outside with paint.

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6.6

Guards

If not ordered from us and thus not included in the scope of supply, guards should be mounted especially on rotating parts such as connecting couplings, in accordance with the safety regulations in force.

6.7

Preservation after installation

 

If the converter is to remain at standstill after installation we recommend preserving the converter as described in Sheet 3.635-006212e.

If there is still some assembly work required around the torque converter during the construction time, measures are to be taken in accordance with section 6.1, par. 8.

6.8

Electric installation

 

Connect and check the provided units and instruments according to the local regulations or to VDE. Instructions to the instruments supplied are included in the enclosed instrument description. Basically please observe the manufacturer's instructions.

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7.

Operating Oil

 

The following work is to be carried out by qualified personnel only (see Safety Information).

If the operating fluid used is not mentioned in our Oil Selection List 3625-006072, check its compatibility with our preservation oil (Shell Ensis Motor Oil 20) or flush the torque converter thoroughly.

The operating oil viscosity must be as low as possible to guarantee satisfactory hydraulic efficiency and air release properties during filling, emptying and turning. On the other hand the working oil must have an excellent lubricating property for the bearings. The only oils suitable for torque converters are high performance, low viscosity oils with excellent lubricating properties and air release capacity.

The oil must be chemically neutral to metals and seals possibly fitted and be nontoxic.

Resistance to aging at max. admissible operating temperature and under high air entrainment must allow a sufficient operating life.

Use a steam turbine oil L-TD 32 according to DIN 51515, part 1 with an air release property < 5 min. at 50 °C DIN 51381 as operating oil. Control the sufficient air release property (behaviour of pump pressures and control stability). In case of queries please consult VOITH.

Regarding other operating fluids examined according to the above aspects, please refer to the enclosed List of Operating Fluids.

The operating oils must not be mixed when being used. Admissible oil mixtures must be clarified with the oil supplier.

For auxiliary units such as connecting couplings and actuator, the amount of lubricant specified by the manufacturer should be checked prior to commissioning and later after the maintenance intervals and should be increased, if necessary.

7.1

Lubricant

 
 

Use Shell Darina 2 grease to lubricate the threaded spindle for the guide vane adjustment mechanism

 

Apply a thin coat of Molykote paste to the thread (external or internal thread) prior to every assembly.

 

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8.

Commissioning

The following work (para. 8.1 - 8.3) is to be carried out by qualified personnel only (see Safety Information).

When operating the torque converter meet the nominal values for temperatures and oil pressures stated in section 9.5.

The torque converter allows a power transmission and speed adjustment only with the specified operating data.

The starting viscosity of operating oil must not exceed 400 mm 2 /s (cSt). For the oils of list 3625-006072 this means a temperature of approx. 0°C.

8.1

Trial run preparations

 

- Check alignment of all equipment considering the heat expansions and shaft misalignments due to operation and correct, if necessary. Record alignment values!

- Check foundation fixing.

 

- Check direction of rotation of prime mover with torque converter uncoupled.

- Check the function on the actuator.

 

- Check the supply of the torque converter with oil from the oil supply system.

- Check piping for leakage.

 

- In case of coupled curved-tooth connecting coupling check for easy displacement of the coupling sleeve and sufficient lubrication.

- Check the function of monitoring instruments or setting of monitoring elements.

 

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8.2

Trial run

 

- Check whether the complete unit is ready for operation.

 

- Check all electrical connections.

 

- Connect the pumps for lube oil supply and for working oil supply to the torque converter at the oil supply system.

- After reaching the operating oil pressure, start the driven machine or monitor the automatic start-up.

- The torque converter is filled with working oil and operated by actuating/switching the servo valve.

 

- Operate the unit and observe smooth running, oil pressures and temperatures.

- Switch off the unit after trial run. Observe the measures for preserveration.

8.3

Measures to be taken at standstill periods and stand-by operation

 

Protect the torque converter against water ingress and humidity. Preserve bright parts accordingly.

For protection against corrosion (oil wetting) start the torque converter every 1 to 2 months for a short time. Do not run the torque converter warm, because there is a risk of dewpoint corrosion.

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9.

Torque Converter Operation

 

The following work (para. 9.1 - 9.8) is to be carried out by qualified personnel only (see Safety Information).

A continuous monitoring of converter maintaining admissible temperatures and pressures means a trouble-free operation and low maintenance.

The starting viscosity of operating oil must not exceed 400 mm 2 /s (cSt). For the oils according to our Oil Selection List 3625-006072 this means an oil temperature of at least

0°C.

To keep good air release property, the oil temperature in the oil supply system must not fall below 45°C.

9.1

Start-up of the unit

 
 

General

 

Start the oil supply for the torque converter. The control valve is at initial position (rest position). Start the drive motor when operating oil pressure is available.

 

Start-up the unit using the torque converter

 

When starting the gas turbine, the spring-loaded piston of the control valve is moved to "filling position" via the servo valve. The torque converter circuit is filled with working oil and the unit is started.

When limit switches are mounted (contact switch - electrical), they are switched by the piston position.

Guide vane adjustment until reaching the self-sustaining speed of gas turbine

The gas turbine is started by adjusting the guide vanes via the actuator (from 0 to 100 %), i.e. it is accelerated until reaching self-sustaining speed.

The change of the guide vane position enables a continuous change of the power transmission.

Completion of unit run-up

 

Drain the working oil circuit of the torque converter after reaching self-sustaining speed of the gas turbine. Move the control valve to "drain position" (initial position) and the guide vanes to 0 % position. Maintain 0 % guide vane position over the complete operating phase of gas turbine.

 

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9.2

Turning the unit via the torque converter

 

When the gas turbine moves from operating condition to turning operation, the control valve remains at "drain position".

During speed reduction, the guide vanes remain at 0 % guide vane position.

If the gas turbine speed drops to below 400 rpm, the gas turbine can be turned by switching on a pony motor.

The working chamber of the torque converter is filled with oil by actuating the servo valve to run up the gas turbine to the speed requested.

The requested turning speed is set by moving the guide vanes to 0 % position.

9.3

Manual emergency operation of filling and draining control

 

Press the manual emergency switch in case of failure of the electronic part on the servo valve.

Switches for manual operations are provided on the front side of the servo valve.

The servo valve carries out this switching function as long as this switch is pressed manually.

Filling as described before is carried out just manually.

 

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9.4

Shutdown of the unit

 

Switch off the gas turbine and stop turning operation.

 

Move the control valve to initial position (drain position). Switch off the oil supply of torque converter when the gas turbine runner stands still. In case of standstill periods please see par. 8.3.

9.5

Operating data

 

Working oil temperature in the flow to the torque converter

nom. value

approx. 60 °C

Working oil temperature in the flow from the torque converter

nom. value

 

< 90 °C 110 °C 120 °C

alarm at

shutdown at

Lube oil temperature in the flow to the torque converter

nom. value

approx. 60 °C

Lube oil temperature in the flow from the torque converter

nom. value

approx. 80 °C

Filling pressure (during operation)

nom. value

approx. 4.0 bar 2.1 bar

alarm at

Control oil pressure (= pressure of oil supply system)

nom. value

approx. 7.0 bar

Torque converter pressure (during operation)

nom. value

12.0 to 18.0 bar < 10.0 bar

alarm

Lube and cooling oil

nom. value

approx. 1.5 bar

Working oil flow rate (during operation)

approx. 16.0 l/sec.

Lube and cooling oil flow rate

approx. 0.6 l/sec.

Turning speed (speed at which pony motor is switched on)

(see data sheet)

 

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9.6

Indication of working oil pressure

 

It

is recommended to fit an oil pressure gauge to the torque converter. However,

an oil pressure gauge must be provided on continuous torque converter operation.

The pressure gauge offers an early detection of faults.

 

The torque converter pressure can change substantially, i.e. as a function of the guide vane position as well as of the motor speed, the speed ratio n T /n P (turbine speed : pump speed) and last but not least as a function of the working oil temperature.

Oil pressure checks can therefore only be compared when guide vane positions, speed ratios and motor speeds are equal.

In

general, an oil pressure check is carried out at approx. 75 % guide vane

opening at full motor speed, with a speed ratio n T : n P of 0.35 - 0.5 and at a

normal operating temperature of between 70 and 90°C.

 

Minimum filling pressure shall be approx. 2.1 bar and minimum converter pressure approx. 10 bar.

9.7

Working oil pressure monitoring

 

It

is advisable to monitor the torque converter pressure using a pressure switch.

Connection see assembly plan. Dependent on the wiring, this switch initiates an

alarm signal if the minimum torque converter pressure of approx. 10 bar is no longer reached during torque converter operation.

9.8

Indication of working oil temperature with monitoring

 

It

is recommended to provide a temperature indicator with monitoring system at

the working oil outlet of torque converter. During torque converter operation the working oil temperature should be approx. 70 - 90 °C. This high oil temperature has a positive effect on the efficiency of torque converter. Max. oil temperature of 100°C must not be exceeded.

Temporary peak temperatures of up to 110°C are still admissible, however, an alarm signal should be given in this case.

A

switch-off signal should be initiated at an oil temperature of 120°C.

 

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10.

Maintenance Intervals and Measures

 

The following work is to be carried out by qualified personnel only (see Safety Information).

10.1

Measures which can be taken when the unit is running

 

Monitor all thermometer and pressure gauge indications during starting operation, rating of gas turbine and turning operation according to the operating data and record for later comparison.

Every 100 operating hours

 

Record and compare all instrument indications.

 

Every 500 operating hours

 

Measure noise and smooth running (vibration), record and compare with recordings which were made under similar conditions.

10.2

Measures which can only be taken when the unit stands still

 

After every standstill of gas turbine

 

Check smooth running of the adjustment mechanism. Leak test to be carried out with the pipework and the connecting couplings.

Every 800 starts or all 2500 hours turning operation, at least yearly

 

Analyse operating oil for aging and take measures according to the oil supplier's instructions.

Inspect and maintain the connecting couplings as per manufacturer's instructions.

Grease the threaded spindle of guide vane adjustment mechanism. See par. 7.1.

Check alignment of torque converter with prime mover and driven machine (alignment values: see par. 6.2).

Check whether all foundations are secure.

 

Visual inspection (corrosion, general condition, etc.) of torque converter.

 

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11.

Overhaul of the Voith Torque Converter

 

We recommend replacement of input and output side bearings of the torque converter as follows:

After 2 000 hours

accumulated starting time (starting motor running, torque converter filled)

 

or

after 20 000 to 25 000 hours

accumulated trailing operation (starting motor stands still, torque converter is turned by the driven machine and cooled by the oil shower)

 

but generally

after an operating time of 5 years the converter in question should be overhauled

To avoid unnecessary delays, we recommend to order spare parts for the general overhaul well in advance. We will be pleased to work out an offer for any inquiry reaching us.

In order to ensure speedy handling of your inquiries, or your orders for service engineers or spare parts, please always indicate the serial number and the exact location of the Voith torque converter and the name of the person in charge.

Only our service engineers or qualified personnel is allowed to do installation work on the torque converters.

 

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12.

Disassembling/Reassembling the Voith Torque Converter

 

Only our service engineers or qualified personnel is allowed to do installation work on the torque converters (see Safety Information).

12.1

General

 
 

An overhaul of torque converter is only possible when it is dismantled.

 

Before starting disassembly take all safety precautions so that the unit can no longer be switched on. Ensure that no dust will develop or dirt (e.g. insulating material or similar) penetrates into the torque converter during the overhaul.

The pump impeller and the turbine wheel in the converter run to each other with minimum clearance. Therefore a careful disassembly and reassembly is a condition.

 

12.2

Preliminary work

 
 

Loosen the electrical supply lines to the rotary actuator. Suspend the rotary actuator on a crane and loosen the screws (050/040) and lift off the rotary actuator including intermediate flange (050/010), remove the coupling disc (050/030) - loose part -.

Remove the cover (020/840). Bend up the tab washer (030/158) and unscrew the hex. screw (030/155). Remove the hex. screw (030/140) and the locking angle (030/150). Extract the bolt (030/130) from the adjusting ring (030/080).

Press the complete bearing with the regulating spindle off the torque converter housing and set it down laterally.

Loosen the oil supply, oil return and leak oil drain piping (see assembly plan). Disconnect the connecting couplings.

Suspend the torque converter on a crane. Loosen the foundation bolts and carefully lift off the torque converter. Swivel the torque converter sideways.

Dismantle the connecting coupling together with the fitted key from the input and output shaft.

Bring the torque converter in vertical position with input side pointing upwards. Support the input side using wooden beams or assembly stands and set the converter down on these.

 

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12.3

Dismantling the control housing

 

Screw two eyebolts or hooks on the front side into the control housing (060/010) and fasten the housing on the crane using a rope. Loosen screws (060/210) and set the control housing (060/010) down laterally. Observe the orifice plate (020/1050) when pressing off.

12.4

Dismantling the input and output part

 

Screw an eyebolt into the center thread of the output shaft and connect it with the crane. Remove the screw plug (020/990) and screws (010/030/030). Remove all screws (020/520) and (020/530). For further dismantling, press the complete output part off against the guide wheel (020/380) and set down laterally on wooden beams. After loosening screws (010/010/030), press the pump impeller off the input shaft. Remove the complete turbine wheel I and II from the guide wheel and guide wheel cover.

Loosen screws (020/280) and remove cover (020/250). Screw an eyebolt into the center thread of the input shaft and lift the input part out of the torque converter housing. For further dismantling, set the input part down laterally on wooden beams or assembly stands.

Please refer to the attached sectional drawings regarding further dismantling steps relative to the input and output part.

12.5

Adjustment of bearing clearances and reassembly of the torque converter

The bearing clearances on the input and output shaft must be adjusted carefully. Bring the shafts in vertical position (shaft end pointing upwards).

Position the input part on the guide wheel (020/380) and the output part on the converter shell (020/500).

Pre-assemble the input part as follows for adjusting the bearing clearance:

- Bolt the guide wheel (020/380) with the guide wheel cover (020/350). Mount the labyrinth bush (020/300) and the filler (020/310) on the guide wheel cover.

- Install the input shaft (010/010/010) together with the antifriction bearings (010/070) and the spacer bush (010/050) in the proper position in the guide wheel cover.

- Mount the antifriction bearing (010/060) in the proper position and fix it with the slotted round nut (010/080) in axial direction on the input shaft.

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Input side adjustment of bearing clearance

 

Set the bearing clearance via the spacer bush (010/050). Measure the bearing clearance by means of a dial gauge arranged between fixed part and shaft face side. Own weight of the rotating parts is 45 kg.

by means of a dial gauge arranged between fixed part and shaft face side. Own weight

How to proceed:

Lift off the input shaft (010/010/010) using a lifting device and attached balance for the upper measuring point with 600 N and for the lower measuring point with 300 N. Ascertain the existing clearance via the attached dial gauge.

Unscrew the slotted round nut (010/080) and remove the input shaft (010/010/010) from the guide wheel cover (020/350). Remove the spacer bush (010/050) from the input shaft. Grind the spacer bush to the nominal length (l nom ).

l nom = l actual - l clearance + 0

0.02 mm.

Repeat assembly. Check the set bearing clearance.

 

Pre-assemble the output part as follows for adjusting the bearing clearance:

- Mount the two antifriction bearings on the output shaft (010/030/010/010) in the proper position up to the shaft collar.

- Fit the spacer bush (010/110) and the bearing retaining ring (020/640).

- Insert the rotating parts into the converter shell.

 

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VOITH Torque Converter EL 10

ZFG

- Mount the antifriction bearing (010/120) on the output shaft.

- Fix the antifriction bearings in axial direction on the output shaft by means of a bush 3623-013151 (mounting aid).

- Install a distance ring with flange 3623-013152 (mounting aid) in the converter shell. When bolting the distance ring with flange, the outer ring of bearing is pressed flush with the converter shell, against spring resistance.

flush with the converter shell, against spring resistance. 99-09-21 cria-HSr (p:\cr\crkddok\3626-) Voith Turbo GmbH

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Output side adjustment of bearing clearance

 

Set the bearing clearance via shim (020/630). Measurement of shim thickness is done by gauge blocks.

How to proceed:

 

Insert two puller screws in the bearing retaining ring (020/640). Insert the puller screws until axial bearing clearance is eliminated. The distance between converter shell and bearing retaining ring is ascertained by gauge blocks within the area of the two puller screws.

This ascertained dimension less 1.0 mm travel of the cup spring results in the thickness for shims.

Remove the puller screws and fit the split shim, with "Hylomar" sealing compound applied on both sides.

Now fit the intermediate ring (020/670), the washer (020/690), the seals and end cover (020/700).

Dismount the distance ring with flange and replace it by installing the labyrinth ring

(020/560).

 

It must be possible to turn the output shaft easily in radial direction, free from play.

Then remove the bush from the output shaft and replace it by pressing on the turbine wheel flange (010/030/010/020). Technical data of oil press fit are indicated in the longitudinal view.

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12.6

Mounting the turbine wheel and output part

 

Mount the core ring (020/440), if removed. Insert the turbine wheels I and II into the guide wheel (020/380) and the guide wheel cover (020/350). Position the pump impeller (010/010/020) on the input shaft and bolt using the socket head screws (010/010/030). Position the output part on the guide wheel and bolt with the torque converter housing.

12.7

Mounting the control housing

 

Install orifice plate (020/1050) in the control housing. Apply a thin coat of sealing compound to the flange side and place the sealing (060/020) on it (adhesive effect). Suspend the control housing on the crane, position it correctly to the torque converter housing and bolt.

12.8

Remaining work

 

Bring the torque converter in horizontal position and mount the connecting coupling hubs. Place the torque converter on the foundation, align and fasten to the foundation. Connect the connecting couplings. Mount the pipes, see assembly plan. Position the rotary actuator with regulating spindle on the torque converter housing. Connect the regulating spindle with the adjusting ring (030/080) (see 12.2 Preliminary work). Mount cover (020/840). Connect the electrical supply line to the rotary actuator.

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Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG - 1

Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

- 1

-

Ersatzteilbestellhinweise:

 

Bitte Fabrik-Nummer des Drehmomentwandlers (s. Typenschild), vollständige Bezeichnung der Teile laut Stückliste und gewünschte Menge angeben.

 

Ersatzteile werden nach jeweils neuestem technischen Stand geliefert.

 

Gehäuse werden anlagenbedingt geliefert.

Deshalb empfehlen wir, diese Teile nur gemäß unserem Angebot zu bevorraten.

Wälzlager, die mit “PA.” gekennzeichnet sind, dürfen nur paarweise (gemeinsam) ausgetauscht werden.

Mit “G.T.” gekennzeichnete Teile sind gewichtstoleriert.

Information required for ordering spare parts:

Please indicate the serial no. of torque converter (see nameplate), full designation of parts in accordance with the parts list and the required quantity.

 

Spare parts will be supplied according to the latest state of art.

 

Customer-specific housings are manufactured.

We would therefore recommend to store these parts only in accordance with our offer.

Replace anti-friction bearings marked with “PA.” in pairs (jointly) only.

Parts marked with “G.T.” are tolerated with regard to their weight.

99-06-09

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Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG - 2

Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

- 2 -

 

Längsschnitt

4 153947 0

Longitudinal section

Pos. Nr.

Benennung

Menge

Item no.

Description

Qty.

010/010/010

Antriebswelle

1

 

Input shaft

 

010/010/020

Pumpenlaufrad

1

 

Pump impeller

 

010/010/030

Zylinderschraube M 16 x 30; G.T. Socket head screw

10

010/010/040

Paßfeder 19,05 x 150 Fitted key

1

010/030/010/010

Abtriebswelle

1

 

Output shaft

 

010/030/010/020

Turbinenradflansch Turbine wheel flange

1

010/030/020

Turbinenrad I

1

 

Turbine wheel

 

010/030/021

Turbinenrad II

1

 

Turbine wheel

 

010/030/022

Zylinderschraube M 12 x 20; G.T. Socket head screw

24

010/030/030

Zylinderschraube M 10 x 25; G.T.; Socket head screw

40

010/030/040

Paßfeder 25,4 x 25,4 x 150 Fitted key

1

010/050

Distanzbuchse

1

 

Spacer

 

010/060

Rillenkugellager 6218 MA C3 DIN 625 Grooved ball bearing

1

010/070

Schrägkugellager 7218 B.MP.UA 80 Angular contact ball bearing

2

 

99-06-09

Voith Turbo GmbH - D-74555 Crailsheim

 

crpi-HSr

Postfach 15 55 Telefon (07951) 32-0 Telefax 32-500

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Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG - 3

Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

- 3 -

 

Pos. Nr.

Benennung

Menge

Item no.

Description

Qty.

010/080

Nutmutter

1

 

Slotted nut

 

010/090

Schleuderring

1

 

Slinger ring

 

010/100

O-Ring 84 x 4 B DIN 3770 NBR 70 O-ring

1

010/110

Distanzbuchse

1

 

Spacer

 

010/120

Lager

1

 

Bearing

 

010/130

Schrägkugellager 7222 B.MP.UA Angular contact ball bearing

2

020/010

Wandlergehäuse Converter housing

1

020/020

Rohrleitung 12 x 1 DIN 2391 Pipe

1

020/170

O-Ring 238 x 5 B DIN 3770 NBR 70 O-ring

1

020/180

Paßscheibe

1

 

Shim

 

020/220

Schaftschraube M 10 x 18 DIN 427; 4.6 Headless screw

1

020/240

O - Ring 10 x 2,2 B DIN 3770 FPM75 O - ring

1

020/250

Deckel

1

 

Cover

 

020/265

Labyrinthscheibe Labyrinth disc

1

020/280

Zylinderschraube M 12 x 60 DIN 912; 10.9 Socket head screw

8

 

99-06-09

Voith Turbo GmbH - D-74555 Crailsheim

 

crpi-HSr

Postfach 15 55 Telefon (07951) 32-0 Telefax 32-500

3626-017391 de/en

(p:\cr\crkddok\3626-)

Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG - 4

Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

- 4 -

 

Pos. Nr.

Benennung

Menge

Item no.

Description

Qty.

020/281

Federscheibe B 12 DIN 137 A3C Spring washer

8

020/290

Zylinderschraube M 12 x 30 DIN 7984 ; 8.8 Socket head screw

2

020/295

Federscheibe B 12 DIN 137 Spring washer

2

020/300

Labyrinthbüchse

1

 

Labyrinth bush

 

020/310

Füllstück

1

 

Filler

 

020/320

Zylinderschraube M 8 x 25 DIN 7984; 8.8 A2C Socket head screw

3

020/330

Federscheibe B 8 DIN 137 A3C Spring washer

3

020/350

Leitraddeckel komplett Guide wheel cover complete

1

020/350/020

Buchse

56

 

Bush

 

020/380

Leitrad

1

 

Guide wheel

 

020/390

Sechskantschraube M 12 x 40 DIN 933; 8.8-A Hex. screw

28

020/400

Federscheibe B 12 DIN 137 A3C Spring washer

28

020/410

Dichtung 775/721 x 0,3 AF3G1 VN1641 Seal

1

020/440

Kernring

1

 

Core ring

 

020/450

Scheibe 22/8,2 x 3 Disc

14

 

99-06-09

Voith Turbo GmbH - D-74555 Crailsheim

 

crpi-HSr

Postfach 15 55 Telefon (07951) 32-0 Telefax 32-500

3626-017391 de/en

(p:\cr\crkddok\3626-)

Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG   -

Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

 

- 5 -

 

Pos. Nr.

Benennung

Menge

Item no.

Description

Qty.

020/460

Zylinderschraube M 8 x 15 VGN 3037; 10.9 Socket head screw

 

14

020/500

Wandlerschale Torque converter shell

1

020/505

Gewindestift M 8 x 10 DIN 914 Set screw

 

4

020/510

Dichtung 775/671 x 0,3 AF3G1 VN1641 Seal

1

020/515

O-Ring 633,48 x 7 VN 3014 NBR 70 O-ring

1

020/520

Zylinderschraube M 12 x 50 Socket head screw

DIN 912; 10.9

40

020/530

Zylinderschraube M 12 x 70 Socket head screw

DIN 912; 10.9

24

020/540

Federscheibe B 12 DIN 137 A3C Spring washer

 

64

020/560

Labyrinthring

1

 

Labyrinth ring

 

020/570

Zylinderschraube M 10 x 30 VGN 3037; 10.9 Socket head screw

 

8

020/580

Federscheibe B 10 DIN 137 Spring washer

8

020/600

Tellerfeder

1

 

Cup spring

 

020/610

Zylinderstift 6m6 x 12 DIN 7 Cyl. pin

1

020/630

Paßscheibe

1

 

Shim