Installation @Maintenan SMB/AEEAVPIALEA\PD// / MUD V eet)CONTENTS Description General Notes Safety Notes Storage Introduction Installation Filling Commissioning & Operation Maintenance Dismounting Dynamic Balancing Disassembly of SMPR & S Assembly SMP R & S Assembly of ALFA P/PD/PDX Part List General Troubleshooting TECHNICAL DATA Coupling model Designation Manufacturing SI. No. Client Order Acceptance No. GA Drawing Number Power Transmission/speed Filling Angle Oil Quantity Fusible Plug Drive Via Outer Wheel Inner Wheel KWIRPM ° (Degrees) Litres teGeneral Notes This Manual will support you in using Fluidomat Fluid Coupling in a safe, proper andefficient way. ‘The Manual contains important information for installation, trouble free and safe operation, along with maintenance instructions. This Manual must always be available on the machine side and should be received and used by every person who works on the coupling The coupling is provided for the client specified power, speed, mounting and bore size conditions. Use for another purpose or beyond it e.g. for higher power and speed is not in accordance with supply conditions and therefore Fiuidomat responsibility ceases under such conditions. Spare parts must be purchased only from Fluidomat. f purchased from other suppliers may under circumstances change the characteristics of the unit and can cause substantial damage to the coupling for which Fluidomat can not assume responsibility. Use proper tools and tackles while installing, dismantling, maintenance and use of coupling Safety Notes 24 The Coupling is manufactured to the state of art and is reliable in the conditions as shipped. Unauthorized modifications are not permissible as they impair its reliability and quality. The coupling must only be used and operated within the scope of the conditions specified in the contract of performance and supply. The customer should ensure that the persons entrusted with installation, operation, care and maintenance as well as repair have read and understood the operating instructions and observe them in all respects in order to:- + Prevent hazard tole and limb of the user and third parties, + Ensure the reliability of the coupling. + Prevent failure and environmental pollution due to incorrect handling. The relevant regulations concerning __industrial_ safety and__ pollution control should be observed during handling, installation, operation as well as during care and maintenance. “the Coupling may only be operated, serviced and repaired by authorized, trained and properly instructed personnel, All work should be carried out with care and with the safety aspect in mind. Allwork on the coupling should only be carried out when itis stationary.The couplings must be secured to prevent accidental start up (e.g. by locking the switch or by removing the fuses and disconnecting the power supply) A notice should bedisplayed at the switch-on point stating that work is in progress on the coupling, The drive unit should be shut off at once if changes in the coupling are detected during operation, such as changed running noises, vibrations, oil leakages etc. Protect the coupling against accidental contact by means of appropriate guards. This guard should also provide protection against hot oil spraying out from fusible plug but without impairing the ventilation of the coupling significantly. The guard should designed such that the fusible plug and oil filler plugs must still be accessible, Always use proper quality of oil for operating the coupling. Observe the instructions on use specified by the manufacturer of oil. During installation of the coupling in units or systems, the manufacturer of the units or system is obliged to incorporate the requirements, notes and descriptions contained in these operating instructions in his own operating instructions. 22 Notes and symbols in the operating instructions:- This symbol draws attention to safety measures which must be observed to prevent personal injury. This symbol draws attention to safety measures which must be observed to prevent damage to the coupling Caution! This symbol draws attention to general operation notes which should be especially observed. Note Storage The coupling is delivered in a preserved state and can be stored up to 6 months provided it is stored in covered, dust free and dry place. If the coupling shall be stored for a longer period of time, an appropriate long-term preservation of alll outer surfaces except the aluminium housing is necessary. Coupling should be kept at least 150 mm above the ground to keep free from attacks of rodents, insects and moisture. Contact with solvents and chemicals should be avoided. If the‘touplings are kept unused for more than 6 months, then their rubber parts like oil seals, fiexibl® coupling rubber elements, 'O' rings etc. should be checked for deterioration if any in their physical characteristics. Rubber parts are affected adversely by moisture, Oxygen, Ozone, extreme temperature, light and solvents etc. It is advisable that the couplings are checked at least once in six months If necessary the rubber parts should be changed after a long storage and before use. 3Introduction Type SMP-R & S & Alfa P are fluid couplings with pulley for belt drive. Type SMP - R & S will be referred as type SMP further in this manual. These couplings are mounted either on motor shaft or on machine shaft and the belt drive is taken from the pulley mounted on the coupling. When mounted on motor shaft they are inner wheel drive and when mounted on machine shaff they are outer wheel drive. Type SMP couplings have two variants - Direct pulley having integral hub bolted on coupling. The integral hub accommodates bearing and oil seal - Pulley type A mounted by key on a hub. Hub accommodates bearing and oil seal andis bolted on coupling Type Alfa P coupling can adopt an externally mounted flanged pulley (EMP). Such pulley can be procured at user end and thus provides flexibility of change of pulley size. They have a bearing housing on the pulley side with location dia d5 in H7 tolerance to adopt an externally mounted pulley (EMP). The EMP will locate in outer wheel at PCD - P as shown in table. Model SMP & M. No. M tapping PCD Alfa P 1 6/4 M6 / M8 87/118 Me / M8 87/118 M10 175 M10 175 M10 215 M10 255 M10 255 M10 290 M12 290 290AlfaP: ‘Type Alfa P are offered in following execution Without Delayfil Chamber With Delayfil Chamber Alfa P-DX With Extended Delayfil Chamber In these SMP & Alfa P Couplings power is transmitted by virtue of oil filled in them but without mechanical connection between input and output. Construction : SMP & Alfa P couplings have an outer wheel, inner wheel and a casing. A shaft is bolted to the inner wheel, This shaft is supported on bearings as shown in figure, Pulley is mounted to the coupling as per the variants described above. Refer Figure. 1, 2 & 3, Type Alfa P can adopt a Delay Chamber as Alfa PD and Alfa PDX described above. Refer Figure 4 “COUPLING TYPE SMP WITH COUPLING TYPE SMP DIRECT MOUNTING PULLEY WITH PULLEY TYPE A ol || vray [th zeMounting Position : These couplings can be mounted horizontally or vertically as shown in Figure 5. ao) = i"Alfa PD & PDX coupling in vertical mounting with delayfil chamber vertically up position i.e. Motor shaft vertically up position is notrecommended. Installation : install the coupling as per following sequence. 1 9Om> m The coupling hollow shaft is to be fitted on the motor or driven machine shaft as may be pre-decided by the user. The procedure remains the same. However in this description we will mention motor shaft for convenience. ‘Check coupling shaft bore, keyway and its matching with motor shaft. Check the motor shaftis running true by dial gauge. Fitthe key on motor shaft. Lubricate the coupling bore and motor shaft. ‘Support the coupling with help of rope and place coupling bore mouth on motor shaft face. Press the coupling on motor shaft with help of mounting bolt which passes through the coupling hollow shaft and threads into motor shaft center tapping. See Figure 6. Aset of thrust spacers provided on this bolt will push the coupling on shaft as the bolt is tightened. While tightening the bolt, ensure that coupling bore is maintained parallel to shaft axis. COUPLING TYPE ALF A-PD & ALFA - PDXNote :- Caution Note :- A\ Filling: Caution Do not hammer the coupling for fitment on shaft. If essential use a soft mallet and tap onthe coupling shaft. F. Dial the coupling pulley to check its concentric running when rotated on motor shaft. G. After mounting the coupling lock it on the center tapping on motor shaft using a locking bolt of proper length and washer. See Figure. 7 H. Align the pulley of coupling to the other pulley and then fix the motor at its position by its foundation holes. The alignment between two pulleys is critical and must be supervised by trained technicians. The alignment should be achieved within 0.1 mm. During installation / mounting or dismounting the coupling weight supporting equipment and hanging elements must be of adequate capacity. If inadequate, it may break and cause serious / fatal injuries. The coupling is supplied without filling oil and therefore oil must be filled before starting coupling otherwise coupling will get damaged within few seconds of running. Fluidomat fluid coupling should be filled to the recommended filling angle and should never be filled to the brim. If the filling angle is not specified, then as a general rule, the filling should be done to 80% of the maximum volume capacity. FILL UP TO THIS LEVEL, FILLING ANGLE MARKED. ON COUPLING. OIL FILLING LEVEL[Caution] Pease ensure that the property fitered oil of right grade and quality i filled in the "———" coupling. Oil should be free from contamination and metallic particles. Metallic particles which gets into oil may cause serious damage to the coupling Contamination in oil will seriously affect the lubrication of bearing and cause damage. Do not exceed filing over 80% volume else it could result in serious damage to the fluid coupling or may result in leakage from oil seal or body ete, For filling open the filling plug marked with an arrow (punched dotted lines) and pour in cold oil. In order to achieve the correct filing, make the arrow marked at a specified angle vertical and allow the excess oil drain. This level should be checked periodically. While filling the oil ensure that motor does not get started accidentally. Therefore lock the starter. > [> For vertically mounted fluid couplings oil cannot be filled with respect of filling angle. In that case filing of oil is recommended by quantity as mentioned in the table. Suitable funnel should be used to fil'oilin vertical mounting Size Allowable maximum oil Filling SMP / Alfa P Alfa PD Alfa PDX 1 is: = = 2 22 = — 3 3.4 3.4 3.6 4 40 44 46 5 5.9 64 6.6 6 78 84 8.6 7 99 10.5 10.8 8 13.4 14.4 14.8 8B 14.0 14.8 15.2 9 20.4 21.4 21.8 10 26.9 28.8 29.3 "1 424 42 45 Care sitould be taken so that oil of different grade is never used and no mixture of oils used as it will adversely affect the performance of fluid couplings. Aiter filing as specified, filing plug should be secured tightly with due care so that no dirt enters through it and there should be no leakage from the plug. 10Oil Specifications Hydraulic oil having following specifications should be used -- Viscosity at 40°C -29-33 CST Flashpoint > 190°C Min. Pour point <(-)24°C Rubber compatibility - Nitrile / Neoprene / Viton One of the following oil can be used on or their equivalent of other companies. HP. Enclo HLPT - 32 Indian Oil Servo system - 32 BP Energol HLP - 32 Caltex Torque fluid - 32 —— Castrol Hyspin AWS - 32 Esso torque fluid - N45 Gulf Hydraulic oil - 32 Shell Togula oil - 32 Mobil Mobil fluid - 125 Note :-] Use of improper oil can damage the coupling and will change operating characteristics of coupling, Commissioning & Operation : Commissioning: The coupling is now ready for commissioning. On the first running, check the oil leakages from the coupling by holding a plain paper in front of coupling. If there is any leakage, the same will be detected by the spray of oil on paper giving the probable location of leakage. In case of any leakage donot run the coupling further and rectify the leekage and then only run the coupling. itis advisable to closely observe the performance of the unit for first few hours and to ensure thatit is not getting excessive hot, the normal working temperature should not exceed 95°C. In case the unitis getting too hot, check the oil level and ensure that proper ventilation has been provided as the operating temperature of fluid coupling is also dependent environmental conditions. 1The temperature of the fluid coupling will rise on overloads. A fusible plug of 130°C+3° response temperature is generally provided for nitrile oil seals which fuses on increase of coupling temperature and drains out all the oil thus stopping the torque transmission and de-loads the motor. ‘Once fusible plug blows out, the motor should be stopped immediately and the cause of overload should be found out and rectified. The response temperature is punched on the face of plug. Fresh oil should be filled in and new fusible plug should be tightened. Never use a solid plug in place of a fusible plug and use genuine Fluidomat fusible plug only. Whenever the coupling has been overheated, the periphery bolts tightening should be checked and they should be tightened with equal torque. Thermal Protection Devices : Type MTP. OR Type IRNC Can be fitted on the coupling. These devices can be hooked up electrically to provide alarm / trip signal in case of type MTP and both alarm trip in case of IRNC. These devices provide valuable safety and environment protection by avoiding spillage and loss of expensive operating fluid Operation: The coupling is now ready for operation. It is advisable to provide guards on the rotating parts to prévent accidents taking into account applicable national and local safety regulations. As the discharge of fluid must be expected in the event of an excessive temperature rise in the coupling, it is advised that the coupling guard in the area of fusible plug should be designed such as to offer protection against splashing of oil without obstructing the airflow around fluid coupling Maintenance : 4. Refill: The Fluidomat coupling should be drained after first 400 hours of operation and refilled with fresh oil. Filling should be done as per the instructions detailed under the heading filling. It should be noted that the torque transmission characteristics of Fluidomat couplings can be varied greatly by adjusting the filling. Before changing the recommended oil filling level, it is better to refer to us. However in no case should you increase the oil filling over 85% volume. Oil should be replaced with fresh il fter every 15000 hours of operation, but filling should be checked periodically at regular intervals. 2.Dismounting : Fluidomat SMP / ALFA - P can be dismounted (removed from motor / machine shaft) easily without disturbing the motor or machine. However, itis advisable to drain it completely before dismounting, Dismounting of the coupling should be done in following sequence 12Ce a)Remove belts from pulley of fluid coupling b) Remove center locking bolt from the shaft on which the coupling is mounted c) Tighten withdrawal boltin the threading provided in the coupling shaft. Hold the shaft and jack off the coupling by jacking bolt. 4) Support the coupling by rope when dismounting Dynamic Balancing : . Alle rotating parts of fluid coupling are dynamically balanced. Additional weights, longer bolts, washers may be found tightened on various components. The location of such additions is very important and if these are opened, they should be replaced at the proper position i.e same position as supplied from factory.3. Disassembly of SMPR&S: For changing casing side oil seal complete disassembly of coupling is not required. Open bolts (29) and jack off the oil seal sleeve (11) through tapped jacking holes. Replace oil seal and gasket or apply gasket compound and refit. For changing oil seal (17) on pulley side same procedure as above should be adopted. Drain outall the oil from the coupling. Open periphery bolts (27). Open bolt (24 and 29) & jack out oil seal sleeves (1) & (11) by tightening the boltin two No. Tapped holes provided for jacking, Press out shaft (3). The shaft alognwith inner wheel (8) and casing (10) will detach from outer wheel (6), Now press out shaft (3). from casing (10) open bolts (28) to disassemble inner wheel and baffle plate (7) from shaft (3) incase of direct mounting pulley. In case of Pulley type A open bolt (25). Press out pulley (16) from hub (15). Remove bearings (18) and (22) from their seats. Disassembly Alfa P Couplings : Open periphery bolts (27). Open bolts (41) and jack off the delayfil chamber (36) from its seat. Jack off pulley (2) from bearing housing (35) by opening bolts (40). Open bolt (25) and jack off Bearing Housing (35). in case of Alfa P couplings there is an additional ol sleeve (11) which can be jacked off by opening bolts (29), Press out shaft (3). The shaft (3) alongwith inner wheel (8) and casing (10) will detach from outer wheel (6). Press out shaft (3) from casing (10). Open bolts (28) to disassemble inner wheel (8) and baffle plate (7) from shaft (3). Remove bearings (22) & (18) from their seats. Assembly SMPR&S: Prior to assembly all parts should be cleaned thoroughly and no dirt should be allowed to enter the fluid coupling. The assembly should be cartied out as per following procedure at a clean place. 1. Fit oil sal (30) in direct pulley (2) or pulley mounting hub (15) in case of pulley type A. Oil seal (30) should be fitted only in case if the coupling mounting is vertical i.e motor shaft vertically downwards. Press bearing (18) in direct pulley (2) or pulley mounting hub (15) as the case may be. Fill grease (only in case oil seal (30) has been provided) in space between bearing (18) and oil seal sleeve (1) 2. Fitplate (5) with help of bolt (26) on outer wheel as shown in Refer figure 10. 143. Fit oil seal sleeve (17) in oil seal sleeve (1) and tighten it on (2) or (15) with help of bolt (24) 4, Fitpulley (2) or (15) on outer whee! (6) with help of bolt (25) 5. Tighten inner wheel (8) along with baffle plate (7) on shaft (3) with help of bolt (28). Use thread retainer compound thread lock of Loctite 242 or equivalent 6. Press this inner wheel and shaft assembly on the outer wheel (6) with (2) or (15) assembly, 7. Check gap between inner and outer wheel should be between 2 “to 5mm 8. Fit oil seal sleeve (23) on oil seal sleeve (11). Apply gasket compound on oil seal face or put a gasket (19) fit this oil seal sleeve + oil seal assembly on casing with help of bolt (29) 9. Apply grease and press bearing (22)in the casing 10. Now place rubber chord on outer wheel collar and apply gasket compound Loctite 518 or its, equivalent on collar face. 11. Press casing (10) on shaft (3) and tighten casing and outer wheel collars together with help of bolts (27). 12. Check free running of shaft (3) in the assembly. 1SECTIONAL DRA\ R Lats 1119 148 8 7 10 loo IS In jn i IS 5 18 16 * THIS OIL SEAL USED ONLY FOR VERTICAL MOUNTING AS PER FIG. E,F & G MOUNTING SHOWN IN FIG 5 FIG. 10 . Assembly of Alfa P/PD/PDX Couplings : 1. Fitoil seal (17) and bearing (18) on bearing housing 2. Fitpplate (5) or oil seal (30) with help of bolt (26) Refer figure 11. 3. Fitbearing housing (35) on outer wheel (6) with help of bolt (25). 16——_—_——_—_-.—_—Yys____ 4. Fit inner wheel (8) alongwith baffle plate (7) on shaft (3) with help of bolts (28). Use thread retainer thread lock of Locatite 242 or equivalent. 5. Press the above inner wheel and shaft assembly on the bearing housing (35) fitted on outer wheel (6). 6. Check gap between inner and outer wheel should be between 2 to 5mm. 7. Fitoil seal (23) in oil seal sleeve (11) in case of Alfa P-coupling. In case of Alfa PD or PDX the oil seal will be fitted in the delayfil chamber (DFC) (36). 8. Press bearing (22) on shaft (3) 9. Fitoil seal sleeve (11) or DFC (36) on the casing (10). 10. Place rubber chord (21) on outer wheel collar and apply gasket compound Loctite 618 or its, equivalent on collar face. 11. Press casing (3) on shaft (3) and tighten casing and outer wheel collars together with help of bolts (27). 12, Check free running of shaft (3) in the assembly. 47MODEL: ALFA-P, ALFA-PD & ALFA- POX 36, * THIS OIL SEAL USED ONLY FOR VERTICAL MOUNTING AS RER FIG. E,F & G MOUNTING SHOWN IN FIG 5 . FIG. 11 18————————— ———————lONlL,!_ 4. Fit inner wheel (8) alongwith baffle plate (7) on shaft (3) with help of bolts (28). Use thread retainer thread lock of Locatite 242 or equivalent. 5. Press the above inner wheel and shaft assembly on the bearing housing (35) fitted on outer wheel (6). 6. Check gap between inner and outer wheel should be between 2 to 5mm. 7. Fitoil seal (23) in oil seal sleeve (11) in case of Alfa P-coupling. In case of Alfa PD or POX the oil seal willbe fitted in the delayfil camber (OFC) (36). 8. Press bearing (22) on shaft (3), 9. Fitoil seal sleeve (11) or DFC (36) on the casing (10). 10. Place rubber chord (21) on outer wheel collar and apply gasket compound Loctite 518 or its equivalenton collar face. 11. Press casing (3) on shaft (3) and tighten casing and outer wheel collars together with heip of bolts (27). 12. Check free running of shaft (3) in the assembly. 47Part List of Fluidomat SMP/ALFA - P 01 OIL SEAL SLEEVE (PULLEY SIDE) 02. DIRECT MOUNTING PULLEY 03. SHAFT 04. LOCK WASHER, LOCK BOLT & LOCK WASHER (NOT FLUIDOMAT SUPPLY) 05. COVER PLATE 06. OUTER WHEEL 07. BAFFLE PLATE 08. INNER WHEEL 09. FUSIBLE PLUG 10. CASING 11. OIL SEAL SLEEVE (CASING SIDE) 13A. BASE PLUG (IMPELLER SIDE) 138. FILLING PLUG (CASING SIDE) 14A.__| FILLING PLUG (IMPELLER SIDE) 14. PULLEY MOUNTING HUB (USED ONLY IN TYPE SMP) 15 HUB MOUNTED PULLEY (USE ONLY IN TYPE SMP) 16 OIL SEAL (PULLEY SIDE) 17 DEEP GROOVE BALL BEARING (PULLEY SIDE / BEARING HOUSING 18. GASKET COMPOUND / GASKET 19. “O" RING. 20. RUBBER CHORD 21 DEEP GROOVE BALL BEARING 22. (OIL SEAL (CASING SIDE) _| 23 HEX, HEAD BOLT, WASHER BETWEEN OIL SEAL SLEEVE AND PULLEY / HUB (USED ONLY IN TYPE SMP) 24. HEX. SOC. HEAD CAP SCREW BTWEEN OUTER WHEEL AND PULLEY HUB 25, HEX. HEAD BOLT & WASHER FOR TIGHTENING COVER PLATE 5 26, HEX HEAD BOLT, WASHER, HEX NUT BETWEEN OUTER WHEEL AND CASING COLLARS AT PERIPHERY. 27. HEX HEAD BOLT, SPRING WASHER, HEX.NUT BETWEEN INNER WHEEL & SHAFT. 28. HEX HEAD BOLT, WASHER BETWEEN OIL SEAL SLEEVE & CASING 28. * OIL SEAL (ONLY FOR VERTICAL MOUNTING) 30. ** BEARING HOUSING) ES ** DELAYFIL CHAMBER 36. “* HEX HEAD BOLT & WASHER FOR BEARING HOUSING & PULLEY 40. * HEX HEAD BOLT & WASHER FOR CASING & DFC. Note : ** Item only for Alfa P, PD & PDX.Recommended Spares : While ordering the spare parts of fluid coupling, part list references number and manufacturing numberas engraved on the casing / on name plate of coupling) should always be quoted along with name and model number of coupling. e.g. 10/81/1402 / SMP - 5 / 11A / B2 f Here 1402 is the manufacturing number. SMP - 5 is the fluid coupling model. 114 and 82 are internal reference No. Recommended spares for trouble free operation S.No. Part Name. PartNo. _|- Recommended Quantity i Fusible Plug 9 2 for every unit in operation 2. Ball bearing 18 & 22 1 for every 3 units 3. Oil seal with casing sleeve 17 & 23 1 for every unit in operation 4. | + MTP Plugs 4 No. for every unit in operation * MTP Plugs are required only if thermal protection system MTP is taken with coupling, General Troubleshooting : TROUBLE CAUSE REMEDY Fusible plug blows off | Oil filing too low Check and increasing filling if or coupling heats up necessary. frequ peaueniy Machine is over loaded or | Check cause of overload or high high power consumption. | power consumption. Cross check HP. selection data Check periphery bolts plugs and oil seal Coupling leakage foil seal leaks, change it Ensure proper mounting and alignment. Motor running too long in | Reduce switchover time from star to star mode delta, Use direct - on - ine starter. Time to run in star mode is maximum 2 seconds. | Excess oll in coupling {foil filing is more than 85% of its i volume, then it will heat up. Reduce i filling upto specified mark, i] Oil seal leaks Coupling shaft bore or ‘Check and replace with components i frequently hub bore is loose of correct bore. Check and rectify cause i of heating. Alignment between coupling | Continuous heating in & other pulley i not proper. " fluid coupling Used after long storage _| Rubber of oll seal aging _| Change oil seal ‘Abnormal sound or Pulley alignment not Check and align pulleys properh vibration proper with the other snd ati leeking bok” . pulley. { Bearing failure Replace bearing Coupling running out on _| Check trueness of mounting shaft. mounting (motor Key is too tight. Check size, Fit and machine) shaft. tolerances. Correct the mountings. Bearing & Oil seal Coupling run dry without | Replace bearings and oil seals: failed prematurely all filing or after fusible plug blow out 20Head Office & Works 7C-84,1'S. Gajra Industrial Area, A.B. Road, Dewas 455 001 (M.P.) India Phone +91-7272-258582/258583/258680 Fa: +91-7272-258681 Emil: fluidomat retin Email : fuidomat@sanchamet.in Email: info@fluidomat.com Regd. Office 117, 1st Floor, "Navneet Darshan’ 16/2 Old Palasia, Indore - 452 001 (M.P.) Phone : +91-731-2564820 Fax : #91-731-2560248 e FLUIDOMAT LIMITED htpp:ilwww idomat.com coe