Eickhoff Gearbox Operating Manual

G 046330XA 17.12.
01
Operating Manual
Power Transmission Division
EnronWind 1.5 / 70.5
3-stage Helical Planetary Gearbox CPNHZ-195
Part number: G 046330XA
Gearbox type: 3-stage helical planetary gearbox
Gearbox No.:
Order No.:
Model: 2001
Revision: 0
Operating Manual
G 046330XA 17.12.01 1
Contents
1 INTRODUCTION........................................................................................................................................ 3
1.1 LEGAL PROVISIONS................................................................................................................................ 3
1.2 THE OPERATING MANUAL....................................................................................................................... 4
2 SAFETY INSTRUCTIONS.......................................................................................................................... 8
2.1 GENERAL SAFETY INSTRUCTIONS........................................................................................................... 8
2.2 SAFETY INSTRUCTIONS FOR TRANSPORT .............................................................................................. 10
2.3 SAFETY INSTRUCTIONS FOR ASSEMBLY ................................................................................................ 10
2.4 SAFETY INSTRUCTIONS FOR STARTING-UP ............................................................................................ 11
2.5 SAFETY INSTRUCTIONS FOR MAINTENANCE........................................................................................... 12
2.6 SAFETY INSTRUCTIONS FOR WASTE DISPOSAL...................................................................................... 12
3 TECHNICAL DESCRIPTION ................................................................................................................... 13
3.1 SCOPE OF SUPPLY............................................................................................................................... 13
3.2 STATE AS SUPPLIED............................................................................................................................. 13
3.3 RATING PLATE..................................................................................................................................... 13
3.4 DESIGNATED USE ................................................................................................................................ 14
3.5 ARRANGEMENT AND PRINCIPLE OF OPERATION..................................................................................... 14
3.6 LIMITS OF APPLICATION........................................................................................................................ 15
3.7 QUALITY ASSURANCE........................................................................................................................... 15
3.8 TECHNICAL DETAILS EW1.5 / 70.5....................................................................................................... 16
4 TRANSPORT AND STORAGE................................................................................................................ 17
4.1 TRANSPORT OF THE GEARBOX ............................................................................................................. 17
4.2 STORAGE OF THE GEARBOX................................................................................................................. 17
5. ASSEMBLY AND STARTING-UP ........................................................................................................... 19
5.1 ASSEMBLY........................................................................................................................................... 19
5.2 COMMISSIONING.................................................................................................................................. 21
6 MAINTENANCE ....................................................................................................................................... 23
6.1 MAINTENANCE TABLE........................................................................................................................... 24
6.2 OIL ANALYSES AND OIL CHANGES ........................................................................................................ 24
6.3 CLEANING THE OIL FILTER.................................................................................................................... 28
6.4 CHANGING THE GREASE PACKING OF THE GEARBOX AND ROLLING BEARINGS....................................... 28
6.5 SEALING OF THE HOUSING PARTING FACES AND COVERS...................................................................... 28
6.6 USE OF LOCTITE.................................................................................................................................. 28
6.7 TROUBLE SHOOTING TABLE.................................................................................................................. 29
7 ANNEX ..................................................................................................................................................... 30
7.1 SERVICE.............................................................................................................................................. 30
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7.2 COMPANY ADDRESS ............................................................................................................................ 30
7.3 AGENCIES ........................................................................................................................................... 31
7.4 MANUFACTURERS DECLARATION ......................................................................................................... 32
8 DRAWINGS AND SPARE PARTS LIST ................................................................................................. 33
9 ACCESSORIES........................................................................................................................................ 34
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G 046330XA 17.12.01 3
1 Introduction
1.1 Legal Provisions
Manufacturer
EICKHOFF Maschinenfabrik GmbH
Hunscheidtstr. 176
D-44789 Bochum
Proper Use
The gearbox is designed exclusively for proper use as defined in this operating
manual (see chapter 3 Designated Use).
Improper Use
The gearbox must not be used for applications other than provided for in the chapter
on 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
Liability
The information, details and notes contained in this operating manual reflect the latest
state on the day of issue. Technical modifications are reserved within the bounds of
the further development of the gearbox. No claims shall therefore be raised for already
delivered 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 the
bounds of the warranty obligations entered into according to the main contract. Claims
for damages, from whatever legal grounds they may be deduced, are excluded there-
from.
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G 046330XA 17.12.01 4
Warranty
Warranty claims shall be brought to the notice of EICKHOFF Maschinenfabrik GmbH
immediately 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 of
an 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
Copyright
This operating manual and all information contained therein are protected by copy-
right. Duplication (including extracts) or conveying to third parties, disclosure or
exploitation of its contents are not permissible without the explicit consent of EICKHOFF
Maschinenfabrik GmbH.
Copyright 1999 by EICKHOFF Maschinenfabrik GmbH
1.2 The Operating Manual
The details and notes contained in the present operating manual shall enable the
active personnel to work safely, properly and efficiently on and with the gearbox. It is
only 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 well
as the textual and pictorial definitions applied in this manual.
Definition of Terms
This operating manual uses a number of important terms which are defined below:
Gearbox
The term "gearbox" as used in this manual shall mean the complete gearbox (see
chapter 3 Scope of Supply).
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G 046330XA 17.12.01 5
EICKHOFF
EICKHOFF Maschinenfabrik GmbH is the manufacturer of the gearbox and shall be
called EICKHOFF hereinafter.
User
The user shall be every natural or legal person who operates the gearbox or gives
instructions to operate the gearbox on his/her behalf.
Operating Personnel
Operating personnel shall be persons who have been charged with and instructed in
the operation of the gearbox. The operating personnel is authorized to carry out
simple 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 corresponding
training, 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 Safety
Instructions.
Skilled Personnel
Skilled 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 Personnel
EICKHOFF personnel shall be skilled personnel employed by EICKHOFF.
Remaining Hazards
Remaining 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 Clothing
Protective clothing shall be the personal protective gear that protects the body against
the hazards arising at work. The protective clothing must comply with the require-
ments of the Equipment Safety Act.
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G 046330XA 17.12.01 6
The circumstances under which protective clothing must and shall be worn are set out
in the applicable local accident prevention regulations.
Pictorial Representations and Textual Displays
The following pictograms and symbols are used in this operating manual to give
salience to important information.
General Hazard
Makes reference to safety instructions which must by all means be observed to avoid
injury to persons and to which no specific pictogram (e.g. one of the following) can
be assigned.
High Electric Voltage
Warns of the hazard of electric shock.
Hot Components
Warns of the hazard of burns when hot system components are touched.
Ecologically Harmful Substances
Warns of the hazard arising from chemical substances unless the said substances are
disposed of in accordance with the applicable environmental rules and regulations.
Safety Related Note
Makes reference to statements on how to work safely on and with the gearbox.
Supplementary Information
Makes 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 executed
precisely in the given order.
This symbol indicates enumerations, the contents of which is of equal priority.
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G 046330XA 17.12.01 7
Structure and Contents of the Safety Instructions
All safety instructions contained in this operating manual are of uniform structure.
Essential Elements of a Safety Instruction
Each 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:
Danger
warns of an imminent hazard to life and health of human beings. Possible
consequences: death or serious injuries
Warning
warns of a potential hazard to life and health of human beings. Possible
consequences: death or serious injuries
Attention
indicates a potential hazard to persons or material property. Possible consequences:
Slight injuries to persons or damage to material property.
Note
indicates 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 Instructions
The gearbox has been built in accordance with the applicable state-of-the-art
standards 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 Gearbox
The 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 prerequisite
that safety devices of the gearbox are in place and fully functional. In the event of
functional disorders or defects, the gearbox must be withdrawn immediately from
service, 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 devices
have to be removed for maintenance after all, they must be refitted immediately upon
completion of the work. All safety devices must be checked for proper operation
before the gearbox is started.
Note
Additions to and/or modifications and conversions of the gearbox which may affect
safety 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 welding
load 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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G 046330XA 17.12.01 9
Operating Manual
The present operating manual primarily aims at ensuring safety-conscious working on
and with the gearbox. It contains safety instructions which must by all means be
observed.
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 not
be started. Ask the skilled personnel of
the user or
EICKHOFF
before you risk exposing yourself to a potentially hazardous situation.
Duties of the User
The 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 manual
and
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 gearbox
should seek a written confirmation to this effect from the personnel.
Active Personnel
Only authorized and instructed personnel shall be allowed to work on and with the
gearbox. Unauthorized persons must be prohibited from operating the gearbox. The
following work must be performed by skilled personnel only:
assembly
starting-up
maintenance.
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G 046330XA 17.12.01 10
The responsible superior shall instruct the operating personnel in safety at work
matters at regular intervals not exceeding one year. The successfully completed
instruction course shall be placed on record and signed by the instructed personnel.
The operating personnel is bound to report any anomalies in the operating behaviour
of 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 longer
ensured.
The personnel working on and with the gearbox must have long hair tied back or
otherwise 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 Transport
Warning
Hazard 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.
Note
Damage to the gearbox by temperature variations
Do not expose the gearbox to excessive temperature variations during transport to
avoid condensing. Protect the gearbox against humidity using tarpaulins for transport.
2.3 Safety Instructions for Assembly
Attention
Hazard arising from inexpert work on the gearbox
Assembly, installation and test run (commissioning) of the gearbox must be carried out
by skilled personnel only.
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G 046330XA 17.12.01 11
Danger
Hazard arising from high electric voltage
Assembly and installation of the electrical components and their testing must be
carried out by skilled personnel (electrical engineers) only.
Note
Before starting up the gearbox, check all lines and bolted connections for tight fit,
leakage and externally discernible damage.
2.4 Safety Instructions for Starting-up
Warning
Hazard arising from inexpert work on and with the gearbox. Hazard arising from
improper 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 or
functional disorders, the gearbox (or the system in which the gearbox is
integrated) must be immediately withdrawn from service and secured against
restarting.
The gearbox (or the system) must not be put into service until all defects or
functional disorders are rectified and the gearbox is fully functional.
Warning
Danger to the health or safety of persons arising from falling objects
Standing or working under suspended loads is strictly prohibited.
Attention
Damage 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 the
functional reach of the safety devices of the gearbox.
Warning
Hazard arising from the starting gearbox
Before starting up the gearbox make sure that no persons are exposed to the hazard
arising from the starting gearbox.
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2.5 Safety Instructions for Maintenance
Warning
Hazard 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 safe
condition and provides a long service life.
Switch off the system in which the gearbox is integrated, as prescribed and
secure it against restarting (e.g. by locking the key-operated switch or by
removal of the fuses in the power supply).
Do not remove any safety devices from the gearbox. Where safety devices
need to be removed for maintenance, they must be refitted upon completion of
the work and checked for proper operation.
Bolted connections separated for maintenance must always be firmly re-
tightened and secured with Loctite.
Note
Damage 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 Disposal
Note
Pollution 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 applicable
environmental legislation and regulations.
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3 Technical Description
3.1 Scope of Supply
The gearbox is delivered by EICKHOFF in a completely mounted state as indicated in
the relevant order specification.
The supplied gearbox shall be checked for completeness upon receipt. Any transport
damage and/or missing components shall be reported immediately in writing.
3.2 State as Supplied
The 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 from
readiness for despatch and transport (no sea transport), subject to indoor
storage.
Labyrinth seals and bearings of the cable bushing are already packed with
grease 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 Plate
The gearbox type and the serial No. indicated on the rating plate and the part
number stated in this operating manual (see chapter Introduction) should always be
quoted in the case of enquiries. The rating plate is securely fixed to the gearbox and
contains 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 (T
2
)
Ratio (i)
Input speed (n
1
) / Output speed (n
2
)
Oil quantity
Oil type
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G 046330XA 17.12.01 14
3.4 Designated Use
The gearbox is used for power transmission between the rotor and the generator. The
rotor 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, in
which 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 present
operating manual be observed.
3.5 Arrangement and Principle of Operation
Design
The three-stage helical planetary gearbox with two helical gear stages and one
planetary stage is noise-optimized by profile and tooth trace corrections. The gear
stages and the planetary stage have helical gear teeth. The sun gear of the planetary
stage is floating for load compensation.
Bearings
The shafts are supported by amply dimensioned rolling bearings. The bearings of the
output shaft are monitored by resistance thermometers.
After assembly the rotor shaft that does not form part of the scope of supply, and the
input planet carrier form a bearing unit together with the shrink disk where the
cylindrical roller bearings of the planet carrier adopt the non-locating bearing function.
Housing
The multi-piece gear housing which is a supporting element, is of torsionally rigid
design. A cast-on flange is provided on the input side and serves as a flexible
mounting to the machine carrier by means of shrunk-in pins. The brakes are bolted to
cast-on faces on the output side.
The housing is fitted with an inspection hole cover on the output side for inspection
purposes. The oil level glass and the oil level monitor are fitted on the same side.
Lubrication
The gearbox has a combined splash and forced-feed lubrication system. The oil is
fine-filtered through a separate filter system.
Cooling
The 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 temperature
reaches 70 C.
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G 046330XA 17.12.01 15
3.6 Limits of Application
Design and operating range of the gearbox are based on the operating details
specified in chapter 3.8 Technical Details.
Consult EICKHOFF before using the gearbox outside its contractual limits of application
or under different operating conditions.
Operating the gearbox at a higher load than the nominal load shortens the service life
of 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 leads
to premature bearing failure.
Reading Measuring Point Signal Type Normal ALARM
OFF
(2)
temperature (T0) oil sump switch 45C70C
(1)
> 85C
temperature (T1) oil sump Pt 100 45C70C
(1)
> 85C
temperature (T2) HSS - A Pt 100 60C85C > 95C
temperature (T3) HSS - B Pt 100 60C85C > 95C
oil pressure (p1) distributor digital 1.5 - 5.0bar < 0.5 bar
differential pressure (p2) clogging indicator switch < 2 bar
(4)
> 2 bar
(4)
Additional Units ON OFF Comment
cooler/fan motor T1 > 60C
T2;T3 > 70C
T1 < 55 C
T2;T3 < 65C
oil sump = T1
HSS - A;B = T2;T3
heater in the oil sump
(3)
T1 < = 5C T1 > 10-15 C oil sump = T1
(1) The temperature rise of the gearbox varies as a function of the operating conditions. At ambient
temperatures ranging from 0C to 30C, the normal continuous temperatures of the oil bath will lie
between 50C and 65C.
(2) The wind turbine must be switched off!
(3) To expedite heating up at oil temperatures of T1 < 15C, the lubricating oil system can be switched on
as well.
(4) If the clogging indicator only responds at oil sump temperatures of T1 < 45C (cold start), an element
change is not necessary.
3.7 Quality Assurance
The EICKHOFF quality system is audited in accordance with DIN ISO 9001 -
design/development, production, installation and servicing - and in accordance with
the European Standard EN 29001 and the British Standards BS 5750.1.
The Certificate (Registration No. 21 143-03) has been awarded to EICKHOFF by
Deutsche Gesellschaft zur Zertifizierung von Qualittssicherungssystemen mbH
DQS (German Association for the Certification of Quality Systems).
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3.8 Technical Details EW1.5 / 70.5
Use Drive of a Wind Turbine Power Plant
Gearbox model 3-stage helical planetary gearbox
Gearbox type CPNHZ-195
Part number G046330Xa
Type of drive three-blade rotor
Rotor diameter 65/70.5 m
Hub height 61.4 - 100 m
Rotor shaft gradient 4.0
Identification
Wind velocity operation: 3 25 / 20 m/s
Drive power 675 1660 1660 kW Ratings
Generator power 600 1500 1500 kW
Dimensions see drawings 009969G1F Size
Weight and packing dimensions see drawings G046330XA
Input torque 792.6 kNm
Max. 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.
Rotational
speeds
Direction of rotation clockwise (when looking at the rotor flange)
Transmission
ratio
1 : 71.766
Type of lubrication forced-feed lubrication and splash lubrication
approx. 35 l (cooling/lubricating circuit ) Oil quantity
approx. 280 l (gearbox)
Lubrication
Oil type Optimol Optigear Synthetik A320
Type Oil cooling by externally erected oil/air cooler
Heat to be dissipated approx. 49 kW / Voil= 68 l/min
Cooling
Filter fineness 10 m abs.
Noise emission Sound pressure level in accordance with the specification
Operating site inland and onshore
Place of erection inside the ventilated nacelle
Ambient temperature -20C to +45C
Open air climate corrosive, saliferous atmosphere; drift sand
Period of operation 24 h/day
Duty cycle 100 %
Operating site/
conditions
Service life 20 years
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4 Transport and Storage
4.1 Transport of the Gearbox
Attention
Danger 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. For
lifting the gearbox, use the lifting eyes, lifting cams or 3-D load rings fitted to the
housing, or ropes which are to be tied around the housing. See the spare parts draw-
ings for the permissible attachment points.
Note
Damage to the gearbox by temperature variations
Do not expose the gearbox to excessive temperature variations during transport to
avoid condensing. Protect the gearbox against humidity using tarpaulins for transport.
Attention
Pollution of the environment by spilling oil
The gearbox must be transported exclusively without oil to avoid spilling.
4.2 Storage of the Gearbox
Note
Damage 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 Conditions
The gearbox must be stored indoors in general. If the actual storage period exceeds
the period stated in chapter State as Supplied, long-term preservation must be
applied.
If storage extends over several years, further preservations may become necessary
depending on the state of the gearbox.
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G 046330XA 17.12.01 18
After very long storage periods - but after 5 years at the latest - a general inspection
must be conducted before starting up the gearbox.
Temporary Storage / Withdrawal from Service
Check the oil level at regular 1-month intervals and turn the gearbox by hand as far as
practicable. When withdrawal from service lasted for more than 1 year, the gear oil
must be changed before the gearbox may be put into service again.
Inspection
The said general inspection can be conducted by EICKHOFF, upon request, either at
their works or - when the gearbox is still integrated in the system - at the user's site.
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G 046330XA 17.12.01 19
5. Assembly and Starting-up
5.1 Assembly
Observe the safety instructions contained in chapter 2 for assembly.
Adequate transport equipment and transport aids must be on hand for transporting the
gearbox. The transport routes to the place of erection of the gearbox must be clear of
obstacles.
The place of erection of the gearbox must be clean and dry.
Mounting the gearbox
Hint
When 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.
Attention
When using solvents and detergents it is imperative to ensure that contact with shaft
seals be avoided.
Warning
Explosion hazard
Provisions shall be made for adequate ventilation when using solvents. Do not smoke.
Note
Under no circumstance must the rust preventative be rubbed off the shaft extensions
or centre holes with emery.
Note
Mount the connecting elements exclusively using the front side threaded holes (acc. to
DIN 332) in the shaft ends.
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G 046330XA 17.12.01 20
Remove the rust preventative from the shaft extensions and centre holes using
a 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 rotor
shaft and the hollow shaft of the gearbox and wash them clean using solvent
and finally lime milk.
Connect the rotor shaft and the hollow shaft of the gearbox by means of the
shrink 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 of
the machine frame.
Aligning the Gearbox
Attention
Damage to the bearings by excessive axial load
The inner axial clearance of the non-locating bearing of the rotor shaft must be 1.5mm
on either side as otherwise the cylindrical roller bearings of the rotor shaft would be
exposed 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 rotor
shaft has an essential inherent axial clearance.
Hint
Additional loads due to misalignment shorten the service life of the gearbox and may
lead to premature failure. Align the gearbox without angular displacement to ensure
smooth and low-vibration operation.
The permissible tolerances for angular and axial displacement of the coupling on the
output side are specified in the manufacturer's documentation (see chapter Acces-
sories).
Mounting on the Machine Frame
Mount the gearbox and the fixed bearing housing of the rotor shaft to the machine
frame using the clamping halves while taking due note of the specified bolt tightening
torques (see chapter Drawings and Spare Parts List).
After Assembly
Check the corrosion preventative and the paint of the gearbox for damage and retouch
where necessary.
Labels affixed to the gearbox such as the rating plate or the arrow indicating the
direction of rotation, shall be taken due note of. They must be free of paint or dirt.
Missing labels must be replaced.
Operating Manual
G 046330XA 17.12.01 21
5.2 Commissioning
Preservation
The 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 points
The greasing points of the gearbox are already packed with the specified grease
quantity and quality ex works. The bearings of the cable bushing and the 'V'-rings are
greased for life.
Note
The greasing points of the 'V' rings must be re-packed when storage extends over one
year.
Oil Filling
Fill 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 quantity
indicated therein is for guidance only. The decisive criterion is the oil level in the
mounting position.
The oil is filled in through the oil drain cock or the filling hole in the inspection hole
cover by means of a filling unit (oil filter fineness < 5 absolute).
Note
In 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 the
oil and to leakage of the rotor shaft seal. Note that the cooling circuit takes approx.
30 l of oil.
Attention
Damage to the gearbox by contaminated oil
No fresh oil that stems directly from the barrel must be filled into the gearbox. The
required cleanliness grade of 17/15/12 according to ISO 4406 (1987) is only ensured
by additional filtration. The inspection hole cover must only be opened for inspection
purposes as otherwise contamination cannot be excluded.
Note
Pollution of the environment by spilled oil
Any oil spilled must be removed immediately using oil binder.
Operating Manual
G 046330XA 17.12.01 22
Make sure that the gearbox is exclusively operated in the permissible direction
of rotation.
Verify that the gearbox is properly mounted.
Make sure that guards for rotating parts (such as couplings, shafts, brakes) are
available.
Forced-Feed Lubrication Systems
Verify 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.
Hint
For adjusting the monitoring and control devices see the operating instructions of the
manufacturer.
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 10C 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-in
period.
Note
The drive must be removed immediately from service when anomalies in the operating
behaviour of the gearbox are found such as unusual gearbox noise or elevated bear-
ing temperature.
Attention
If anomalies such as elevated bearing temperature, tripping of the oil pressure sensor
or 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 6.7
Trouble Shooting Table. If no cause can be found you should contact our service
department.
Operating Manual
G 046330XA 17.12.01 23
6 Maintenance
Note
Make 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 chapter
Application 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 Spare
Parts List).
Warranty expires when unauthorized repairs are carried out during the warranty
period.
Note
All operating fluids, consumables and replacement parts must be disposed of in a safe
and 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 the
oil change
every
1 - 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 the
oil change
every
1 - 2 years
Change oil filter insert
Gearbox - change oil See chapter 6.2 Oil Analyses and
Oil Changes
Gearbox - change grease
Regrease grease packed rolling bearings
See chapter 6.4 Changing the
Grease Packing of the Gearbox and
Rolling 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 oil
samples) 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 the
flange piece between the pump and the oil filter by means of appropriate sampling
devices. The following procedure should be generally followed for any sampling points
on 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 Analysis
The analysis should cover the following parameters:
Parameter Limiting Values
Visually clear
Typical odour
Appearance
Product-specific colour
Viscosity 288 352 cSt at 40C
Density Changes due to ageing in conjunction with a higher viscosity
Neutralization number (NZ) 2.2 4.8 mg KOH/g
Increase of NZ versus the
fresh 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 max
Chromium 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 max
Metal particles 35 mg/ml
Particle quantity (PQ) index 60
The above oil limiting values serve for guidance and provide the basis for a precise
assessment as to whether single values may be exceeded.
Oil Change
The gear oil must be drained completely and replaced with fresh oil on expiry of the oil
change interval and/or as a result of the oil analyses. If heavy contamination is found
the gearbox must be rinsed with diesel fuel and/or flushing oil. If the oil contamination
rises to a permanent value of 19/17/14 according to ISO 4406, premature failure of the
bearings is to be expected.
Operating Manual
G 046330XA 17.12.01 27
Note
All operating fluids, consumables and replacement parts must be disposed of in a safe
and environmentally protective manner in accordance with the applicable environ-
mental legislation and regulations.
Warning
Danger 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.
Warning
Hazard of burns from hot components or operating fluids
The oil bath may attain temperatures as high as 90 C with the result that also the
gearbox components may be subjected to a high temperature rise. Wear safety gloves
where necessary when conducting the oil change.
Attention
Damage to the gearbox by contamination
Proper operation and the service life of the gearbox as a whole are affected when
contaminants penetrate into the oil circuit. Therefore pay attention during maintenance
of the gearbox that no fibres of cleaning rags, sand or foreign material enter the oil
circuit.
Note
The 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 a
filling unit (oil filter fineness < 5 absolute).
Close screw plug and oil drain cock.
Operating Manual
G 046330XA 17.12.01 28
Note
In 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 the
oil and to leakage of the rotor shaft seal. Note that the cooling circuit takes approx.
30 l of oil.
6.3 Cleaning the Oil Filter
Please note the operating instructions of the oil filter manufacturer.
6.4 Changing the Grease Packing of the Gearbox
and Rolling Bearings
The 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 is
not necessary.
6.5 Sealing of the Housing Parting Faces and Covers
The parting faces of the housing and the fitting surfaces of the covers are sealed with
HYLOMAR SQ 32/M jointing compound against escaping oil. The inspection hole
cover is fitted with a paper seal which must be checked before re-mounting the cover
and changed where necessary.
All sealing surfaces must be cleaned and re-sealed with HYLOMAR or an equivalent
jointing compound after every disassembly and re-assembly.
6.6 Use of Loctite
The 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 or
shock 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 that
the 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 the
entrapped compressed air can escape.
Operating Manual
G 046330XA 17.12.01 29
For Bolted Connections
Type of
Connection
Nominal
Thread Size
[mm]
Product Information Notes on the Drawings
Loctite product 243
Colour: blue
Breakaway torque DIN 54454,
M10 bolts: 14-34 Nm
Separable,
medium strength
(connection can be
separated using
standard 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 262
Colour: red
Breakaway torque DIN 54454,
M10 bolts: 15-50 Nm
Inseparable,
high strength
(connection that
need 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 Table
Anomaly 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 bearing
temperature
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 coupling Louder noise in the area of
the 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 sump
temperature
Cooler defective Contact service department.
Shut down system, if required.
Pressure sensor triggers
alarm
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 connection
using a pressure gauge.
!G
!GENTITL
!GENTITL
!GENTITLE-LL
Blatt Nr. / sheet no:
Bltter / sheets:
Ausgestellt /
Rev.:
drawn:
2
17981 C3
Getriebe EW 1.5 Serie
gearbox EW 1.5
SP
10.10.2001
6.6.2001
2
lkhler
Getriebe Getriebe
Schmierpumpe
Heizpatrone 1
Heizpatrone 2
32 33 34 27 28 29 30 31 13 14 15 16 19 17 20 18 21 22 23 24 25 26 1 2 3 4 5 6 7 8 9 10 11 12
PE U1 V1 W1
V2 U2 W2
M
W2 V2 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
GX1
1 2 3 4 5
oil level oil-pressure switch
oil
bearing A
2
1
2
1
10 6 7 9 8 13 11 12 15 14
4
2
2
1
-
1
+
3
16 17 18 19 22 20 21 23 24
gearbox
temperature temperature
gearbox
Abschirmung
Getriebe
lstand
Lager A
Temperatur
Getriebe
l-Druckschalter
Temperatur
lsumpf
gearbox
lubricating pump oil cooler
gearbox
heater
heater
element 2
element 1
input (on top)
input (on top)
Eingang (oben)
W103
W102
W104
W105
W201
W202
W203
W204
Nicht benutzte Einfhrungsbohrungen mit
zugehrigen Verschlusstopfen verschliessen.
Close unused entry holes with
correspondending closing plugs.
W204 W201 W202 W203
W106 W101 W103 W102 W104
121212123
12
g
r
/
g
e
12
g
r
/
g
e
g
r
/
g
e
b
l
b
r
s
w
g
r
/
g
e
b
l
b
r
s
w
2
-1R3
1
2
W106
1
Lager B
bearing B
Temperatur
temperature
W105
(-1B3)
bertemperatur
Getriebe
gearbox
temperature
overload
W107
(-1S4)
Anschlussplan/connection diagram
26 25 27
PE
NAME DAT.
R
E
V
I
S
I
O
N
9.9.01 SP
SP 10.10.01
-1B2
W101
1
1
P
2 3
3 2
verschmutzung
Feinfilter-
Getriebe
fine clear filter
gearbox
4
1
-1S4
-T
2
1
W107
23
36 35
Operating Manual
G 046330XA 17.12.01 34
9 Accessories
E_NF1310_2SO.doc/16.02.2001/B. Schn
Hydac Filtertechnik GmbH Brbel Schn / Abt. FFVI
Postfach 1251 Telefon (06897) 509-784
D-66272 Sulzbach/Saar Telefax (06897) 509-300
Industriegebiet E-Mail: [email protected]
D-66280 Sulzbach/Saar
Low Pressure Filter
NF BN/HC 1310 D P 10 D 2.0 /-V-L24-SF50
Artikel-Nr.: 01274404
SPARE PARTS LIST
MAINTENANCE INSTRUCTIONS
The warranty offered pursuant
to our Terms of Sale and
Delivery is applicable only in the
event that original HYDAC
components are used and work
is carried out solely by properly
trained and qualified personnel.
Seite 2
INDEX
1. MAINTENANCE UNSTRUCTIONS
1.1 Safety Instructions
1.2 Installation
1.3 Commissioning
1.4 Equipment Requiered For Changing The Element
1.5 Torque Ratuings For Clogging Indicators
2. MAINTENANCE
2.1 General
2.2 Maintenance Procedures
2.3 Interval Between Chanfing Elements
3. CHANGING THE ELEMENT
3.1 Removing The Element
3.2 Fitting The Element
4. SPARE PARTS
4.1 Spare Parts Drawing NF 1310
4.2 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 pressure
of 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
SW
NF 1310
SW 27 SW 19
1.5 Torque Ratings For Clogging Indicators
TYPE max. Moment
VD ... 25 Nm
VR ... 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 for
use, 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 9500
hours. 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, according
to 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 cleaned
immediately.
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 the
filter design and the conditions to which the filter is subjected). When the filter element is
subjected to high dynamic loading it may prove necessary to change the element more
frequently. The same applies to commissioning, repair work, oil changes etc. in the hydraulic
system.
Standard clogging indicators respond only, if there is a flow through the filter. As to electrical
clogging indicators, the signal can also be processed and indicated on the control panel
continuously until acknowledging the fault by eliminating it (i.e. changing the filter element and
cold-starting the system).
If the clogging indicator only responds upon cold-starting, the filter element may not yet require
changing.
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 contamination
residue 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-sized
particles. 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 sealing
surfaces.
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 clean
hydraulic medium as needed.
2. When fitting a new filter element check that the designation of the new filter element corresponds to
that 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 with
environmental 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
Item
Cons.
of
Designation Qte. NF 1310
1. FILTER ELEMENT 1300 R 010 BN3HC /-V 1 00311672
1.1 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 01274864
2.1 Filter element 1 0240 D...
2.2 O-ring 1 34 x 3,5
3. VR 0 A.0 1 (2) 00306006
3.1 Locking screw 1 VR...
3.2 O-ring 1 18 x 2,5
4. VM 2 D.0 /-V-L24 1 00316556
4.1 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 5,33
5.2 O-ring (Element 2) 1 34 x 3,5
5.3 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 5,33
6:2 O-ring (Element 2) 1 34 x 3,5
6.3 O-ring 3 189,87 x 5,33
6.4 O-ring (VR 0 A.0) 2 18 x 2,5
6.5 O-ring (VD 0 A.1) 1 15 x 1,5
6.6 Profile sealing ring (VD 0 A.1) 1 VD...
6.7 Locking screw VSTI 1 G
6.8 Locking screw VSTI 1 G
*) The order number will be fixed if necessary.
NOTE:
All details in this brochure are subject to technical modifications !
Electronic Pressure Switch
EDS 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 points
and 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
(G A male thread to DIN 3852). The connection adaptor ZBM 11 is available as an
accessory 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 connection
must be mechanically decoupled via a Minimess hose. Mounting clamps are available as an
accessory (see point 12.2 "Accessories - for mechanical connection").
The electrical connection should be carried out by a qualified electrician according to the
relevant regulations of the country concerned (VDE 0100 in Germany). The pressure switch
housing must be earthed properly at the same time. When fitted into a hydraulic block it is
sufficient 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 electromagnetic
interference:

Make line connections as short as possible.
Use screened lines (e.g. LIYCY 4 x 0.5 mm
2
)
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 switching
points,
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 the
actual pressure.
2 s
In the basic settings the display can be altered. For example, the maximum value can be
permanently displayed. This is the largest measured value which has been recorded since
the unit was switched on or was last re-set. A switching point can likewise be permanently
displayed 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 causes
the 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 the
basic setting:
5.1.1 Switching point setting (SP)
One switching point and one hysteresis can be set for each switching output. The respective
output switches when the pre-set switching point is reached and switches back when the
pressure 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 each
case 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 lower
switch-back value is just below the lower switching value (lower switching value minus three
times the increment, see point 5.4). The upper switch-back value is just above the upper
switching value (upper switching value plus three times the increment, see point 5.4). The
area between switching and switch-back value forms a safety zone which prevents unwanted
switching 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 switching
values (including the safety zone) are greater than 0 bar and lower than the nominal
pressure 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 valuet
Switching value
Switch-back value
Switching value
hi.1
5.3. Setting the switching points, hystereses and/or critical values for the window
function
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
pressure
display
press mode key until display set switching point
H
the required
parameter 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 point
and/or upper
critical value
in bar
Hysteresis and/or
lower 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 0.2
100 1.5 .. 100 0.5 .. 99.0 0.5
250 3.0 .. 250 1.0 .. 248 1.0
400 6.0 .. 400 2.0 .. 396 2.0
600 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 altered
via 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 display
mode 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 Setting
range
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 (T
on
1)
Time in seconds which must elapse, once the
particular switching point has been reached or
exceeded, before switching will occur.
0.00..75s 0
Switch-off delay switching output 1 (T
off
1)
Time in seconds which must elapse, once the
pressure has fallen below the particular switch-back
point, before switching will occur.
0.00..75s 0
Switching output 2, as above
Primary display (Primary)
Display value which should remain permanently in the
display:
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 zero
point. This is possible in the range +/- 3 % of
the units nominal pressure range.
new appears in the display when a calibration
is carried out in the permissible range,
otherwise Err is displayed.
This function is useful for example if there is always a
residual pressure in the system which should however
be displayed as 0 bar.
Please note:
Following a zero point adjustment, for example, on a
600 bar unit, a pressure of up to 18 bar is displayed as
0 bar. Before any work is carried out on the hydraulic
system, ensure that the system is de-pressurised.
YES/ NO NO
Version number (Version)
Display of the current software version (for reference
only)
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 the
settings. The operating programming enable can be set or removed during operation. It
provides protection from unintentional alteration. A programming disable via the main
programming enable has the effect that no change to the settings can be carried out during
operation. This serves, for example, as a safety function or as protection against
unauthorised alterations.
7.1 Altering the operating programming enable
mode mode
G
3 s
pressure
3 s
press both arrow
keys simultaneously
and hold down for 3 s
use or to alter setting,
OFF
ON
= programming disabled
= programming possible
G G
display
(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
display press both arrow
keys simultaneously
and hold down.
use or to alter setting,
OFF
ON
= 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 switched
over. 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 be
acknowledged 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 resulting
switch-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 the
switching 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 strong
electromagnetic 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 are
strong electromagnetic interference or a component fault.
Corrective action: Switch the unit off and on again. If the error message is still
displayed, 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 bar
Overload pressures: 32, 80, 200, 500, 800, 900 bar
Burst pressure: 300 % FS
Output 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
Switching outputs:
Type: PNP transistor output
Switching current: max. 1.2 A
Switching cycles: 100 million
Reaction time: approx. 10 ms
Ambient conditions:
Temperature range of medium: -25 .. + 80 C
Ambient temperature range: -25 .. + 80 C
Storage temperature range: -40 .. + 80 C
Nominal temperature range: -10 .. + 70 C
- mark: EN 50081-1, EN 50081-2, EN 50082-1, EN
50082-2
Vibration resistance: approx. 10 g / 0..500 Hz
Shock resistance: approx. 50 g / 1ms
Other data:
Supply voltage: 20 .. 32 VDC
Current consumption: approx. 100 mA (no switching output)
Safety type: IP 65
Hydraulic connection: G A DIN 3852
torque rating 17 .. 20 Nm
Parts in contact with medium: stainless steel, seal: FPM
Material of housing: tube: stainless steel
keypad housing: PA6.6 Gf30
Display: 3-digit, 7-segment LED, red,
height of digits 9.2 mm
Weight: 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 A
EDS 345-1
1
2
3
+
-
20..32 V
SP 1
Imax. 1.2 A
EDS 346-1
1
3
4
+
-
20..32 V
SP 1
Imax. 1.2 A
EDS 346-3
1
3
4
+
-
20..32 V
2
SP 1
RL
I = 4..20 mA
analogue
Imax. 1.2 A
EDS 344-2
1
2
3 +
-
20..32 V
4
Imax. 1.2 A
SP 1
SP 2
Imax. 1.2 A
EDS 344-3
1
2
3 +
-
20..32 V
4
SP 1
RL
I = 4..20 mA
analogue
Imax. 1.2 A
EDS 346-2
1
3
4 +
-
20..32 V
2
Imax. 1.2 A
SP 1
SP 2
Imax. 1.2 A
Imax. 1.2 A
SP 1
SP 2
EDS 348-5
1
3
4
+
-
20..32 V
5
2
I = 4..20 mA
analogue
RL
11. Model code
Series no..
(determined by manufacturer)
Type of connection, mechanical
4 = G A male thread
Type of connection, electrical
EDS 3 4 X - X - X 0 XX - 00
4 = 4 pole Binder plug, series 714 M18
Pressure ranges in bar
016, 040, 100, 250, 400, 600
Modification number
000 = 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 "
Output
1 = 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 type
3 = 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 08
series 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 lead
ZBE 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 G female thread - GA male thread for optimum
alignment of the pressure switch
Colour code:
Pin 1: brown
Pin 2: white
Pin 3: blue
Pin 4: black
Colour code:
Pin 1: brown
Pin 2: white
Pin 3: blue
Pin 4: black
Pin 5: grey
ZBM 300 clamp for wall-mounting the EDS 300 (material: polypropylene)
Mounting:
Glue damping strips into the recesses of
the 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 they
engage.
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 Massar i
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So 44
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-
BETRIEBSANLEITUNG
SERVICING INSTRUCTIONS LLUFT KHLAGGREGATE
OIL-AIR COOLERS UNITS
COOLING SYSTEMS
Via Industria 6814 Lamone, Switzerland
INTERNET : http ://www.hydac.ch
tel. : 091 / 611 17 30
fax : 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.
INSTALLATION
The mounting position of every cooler is optional. In all cases, unrestricted air flow should be ensured. The ideal
distance on the suction and pressure side is described in the Oil-cooler catalogue. The inlet and outlet of the hydraulic
connection are labelled. The coolers must only be connected using hydraulic threaded connections. The hydraulic
connection on the heat exchanger should be dry and the nut should only be tightened by means of two spanner. For
some small cooler elements the highest permissible torque rating on the threaded connections is given on the name
plate 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 minimum
cross-section: OKA-R1,2 max. flow 12 l/min, min inside diameter 19 mm; SCA1,2 max. flow 15 l/min, min inside
diameter 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 is
more than 2m, the cross-section should be correspondingly larger. The maximum permissible viscosity is 180mm
2
/sec
(COLD START).
A wrong rotation may damage the pump ! Verify always the direction of the pump. PLEASE NOTE: UNITS WITH FEED
PUMP MUST NEVER RUN WITH CONNECTIONS CLOSED. However, a short dry run with open connections (in order
to 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 the
corresponding sticky label (see dia.2). The hydraulic motor reversible is equipped with a tank line. This line must be
connected to the tank.
WORKING PRESSURE
On units with a feed pump the maximum working pressure of 6 bar must not be exceeded. On units without a feed pump
the maximal working pressure is 15 bar. A by-pass valve can be fitted as an optional extra to protect the unit against
pressure peaks.
ELECTRICAL CONNECTION
Oil coolers with electric motors (three phase to IP55) have a terminal block connection, to VDE (or prevalent country
regulations). PLEASE ENSURE CORRECT VOLTAGE AND FREQUENCY. The direction of rotation is given on the
corresponding sticky label (see dia.2).
CONTROL
Simple temperature control can be achieved using the optional thermostat. The thermostat can be built into the unit or
fitted to the tank
COMMISSIONING
Check for correct direction of rotation of the fan as given on the corresponding sticky label (see dia.2), as well as the
correct connection and the free flow of the oil.
MAINTENANCE
The HYDAC coolers units are virtually maintenance-free. A very dusty environment might necessitate periodic cleaning
of the heat exchanger. Cleaning should only be done using a soft brush to avoid damaging the fins of the element which
could reduce the performance of the unit. On OKAF coolers (which are fitted with a filter) the contamination level of the
filter element has to be monitored. For highly contaminated air an optional air filter mat can be fitted to the suction side
of the fan.
CLEANING AND CHANGING OF THE FILTER ELEMENT
Unscrew the filter housing and remove the contamination retainer together with the filter element. Dispose of dirty
residues 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 REPORTS
All HYDAC cooler units are subjected to a final quality test. A test report is compiled which documents the following
tests: function test, leaking-tightness of the cooler element (pneumatic or hydraulic test), noise level (only if it deviates
from the standard), double-check of customers order details. This internal document is available on request.
IK.20.E6.03 Januar 1997
Pressure and Temperature Controls
Datenblatt
Pressostate und
Thermostate
Typ KPS
Datenblatt
2 IK.20.E6.03
bersicht
ISO 9001
Qualittszulassung
bersicht ber KPS Pressostate
Bereich Weitere
-1 0 10 20 30 40 50 60 bar P
e
Typ 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 P
e
Typ Informationen
bar Seite
2.Pressostate Typ KPS fr hohe Drcke und stark pulsierende Medien
1 - 10 KPS 43 3
4 - 40 KPS 45 3
6 - 60 KPS 47 3
bersicht ber KPS Thermostate
Bereich Weitere
-50 0 50 100 150 200 250 C C Typ Informationen
Seite
-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 nach
der internationalen Norm ISO 9001. Damit
erfllt Danfoss die Forderungen der
internationalen Norm in bezug auf Produkt-
entwicklung, Konstruktion, Produktion und
Vertrieb. BSI kontrolliert regelmig, ob
Danfoss die Forderungen der Norm einhlt.
Gleichzeitig kontrolliert BSI auch laufend das
Danfoss-eigene Qualittssystem.
Pressostate und Thermostate, Typ KPS
1. Standardpressostate
Datenblatt
IK.20.E6.03 3
KPS-Pressostate sind druckgesteuerte
Wechselschalter, deren Kontaktstellung vom
Druck am Eintrittsstutzen und dem
eingestellten Skalenwert abhngt. Die in
kompakter Bauweise konzipierten und dicht
gekapselten Gerte sind robust, sto- und
erschtterungssicher und sie gengen
Einfhrung
1. Pressostate
*Effektiver Druck (berdruck)
Terminologie
Bereichseinstellung
Druckbereich, in dem das Gert ein Signal
abgeben kann (Kontaktwechsel).
Differenz
Unterschied zwischen dem Schlie- und dem
ffnungsdruck (siehe auch Abb. 8 Seite 7).
Zulssiger berdruck
Hchster andauernder oder hufig wiederkehrender
Druck, dem das Gert ausgesetzt werden darf.
Max. Prfdruck
Hchster Druck, dem das Gert bei der Inbetrieb-
setzung des betreffenden Systems z.B. in
Verbindung mit einer Dichtheitsprfung ausgesetzt
werden darf. Es darf sich somit nicht um einen
wiederkehrenden Systemdruck handeln.
Min. Berstdruck
Druck, bei dem die Dichtheit des druck-
empfindlichen Elements gewhrleistet ist.
KPS 43, 45, 47
KPS 31, 33
KPS 35, 37, 39
Bei Bestellung bitte Typ und
Bestellnummer angeben
Technische Daten und
Bestellung
Regel- Einstellbare Zulssiger
bereich bzw. feste Betriebs- Max. Druck- Bestell-Nr. Typ
(p
e
)*) Differential druck P
B
Prfdruck anschlu
[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 fr hohe Drcke und stark pulsierende Medien
Regel- Einstellbare
bereich Diff. (siehe auch
Zulssiger

Max. Max. Druck-
(p
e
)*) Abb. 1, 2 und 3)
berdruck Prfdruck Berstdruck anschlu
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: Bereichseinstellung
B: Differenzskala
C: Erreichte Differenz
Abb. 1 Abb. 2 Abb. 3
Pressostate, Typ KPS
sowohl bei einer Innen- als Auenmontage
hohen Ansprchen.
Die Pressostate werden fr Regel-, Warn-
und berwachungsaufgaben an Diesel-
aggregaten, Kompressoren, Kraftwerken
und Schiffen eingesetzt.
Datenblatt
4 IK.20.E6.03
Kontaktsystem
Einpoliger Wechselkontakt (SPDT):
Kontaktmaterial: Silber, goldbeschichtet.
Kontaktlast
1. Wechselstrom:
Ohmsche Last 10 A, 440 V, AC-1
Induktive Last 6 A, 440 V, AC-3
4 A, 440 V, AC-15
Startstrom max. 50 A (blockierter Lufer).
2. Gleichstrom: 12 W, 220 V, DC-13
Siehe Kurve Abb. 4.
Abb. 4. d.c.-Belastung
Kurve A zeigt die maximale Belastung.
Die schraffierte Flche B: Zulssige
Belastung des Goldbelags der Kontakte.
Medienberhrte Werkstoffe
Wellrohrkapsel: 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, 37,39
Wellrohr: 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.
Umgebungstemperatur
KPS 31 - 39: 40 bis +70 C
KPS 43 - 47: 25 bis +70 C
Medientemperatur
KPS 31 - 39: 40 bis +100 C
KPS 43 - 47: 25 bis +100 C
Fr Wasser und Seewasser jedoch max. 80 C
Erschtterungssicherheit
Vibrationsfestigkeit im Bereich 2-30 Hz
Amplitude 1,1 mm und 30-300 Hz, 4 G.
Schutzart
IP 67 gem IEC 529 und DIN 40050.
Pressostatgehuse aus lackiertem
Aluminiumdruckgu (GD-AISi 12). Deckel
mit vier Schrauben befestigt. Bei einer
Demontage ist der Deckel durch eine
Schlaufe gesichert. Die Kapselung kann mit
Sicherungsdraht plombiert werden.
Kabeleingang
Pg 13,5 fr Kabeldurchmesser von
5 bis 14 mm.
Identifikation
Die jeweilige Typenbezeichnung und
Bestellnummer ist seitlich am Gert
eingeprgt.
Skalengenauigkeit
KPS 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 400.000
Schaltungen (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, Norwegen
American Bureau of Shipping
Lloyds Register of Shipping, England
F Germanischer Lloyd, BRD
Bureau Veritas, Frankreich
Umfat Thermostate und Pressostate
mit festem Fhler und Thermostate mit
armierten Kapillarrohr.
EN 60 947-4-1
EN 60 947-5-1
U Underwriters Laboratories Inc., USA
Schiffszulassungen Registro Italiano Navale, Italien
P Polski Rejestr Statkw, Polen
MRS Maritime Register of Shipping,
Ruland
Nippon Kaiji Kyokai, Japan
Datenblatt
IK.20.E6.03 5
Zubehr
Gewicht:
KPS 31 - 39 ca. 1,0 kg
KPS 43 - 47 ca. 1,3 kg
Mabilder und Gewichte
Teil Beschreibung Bestell-Nr.
G
3
/
8
berwurfmutter, Nippel und
berwurfmutter mit Nippel Dichtung (10 mm auen) zum 993N3572
Anlten
G
3
/8 berwurfmutter, Nippel und
Dichtung (10 mm auen/6.5 mm
berwurfmutter mit Nippel
innen) zum anschweien 017-4229
Reduzierstck G
3
/
8
X
7
/16 - 20 UNF (
1
/
4
flare)
Reduzierstck mit Dichtung 017-4205
Muffe G
3
/
8
x
1
/8 - 27 NPT innen mit Dichtung 060-3334
Muffe R
3
/
8
auen 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
Nippel
G
1
/
4
A x M10 auen x 1 mit Dichtung 060-3338
Dmpfschleife mit
1
/4 Brdel berwurf-
mutter und 1 m Kupferkapillarrohr. Wird
die Dmpfschleife in Verbindung mit Ge-
Dmpfschleife rten mit
3
/8 RG Anschlssen verwendet, 060-0071
ist auerdem ein Reduzierstck, Bestell-
nummer 993N3551, erforderlich.
Informationen bezglich der Lnge des
Kapillarrohrs bei Danfoss erhltlich.
Dmpfschleife
Dmpfschleife mit berwurfmutter G
3
/
8
und 1,5 m Kupferkapillarrohr
060-1047
Dmpfschleife mit berwurfmutter G
3
/
8
Dmpfschleife armiert 1 m armiertes Kupfer-Kapillarrohr. 060-3333
Standarddichtung wird mitgeliefert
Datenblatt
6 IK.20.E6.03
Montageverhltnisse Einstellung
Deckel entfernen, Sperrschraube 5 (Abb. 6)
lsen und darauf mit Hilfe der Spindel 1 unter
gleichzeitigem Ablesen der Skala 2 den
Bereich einstellen. Bei Gerten mit einstell-
barer Differenz erfolgt die Differenzeinstellung
mit der Spindel 3. Die erreichte Differenz kann
entweder direkt auf der Skala 4 abgelesen
oder soweit es die Typen KPS 43, 45, 47
betrifft durch Ablesen des Skalenwerts und
Benutzung von Nomogrammen, Abb. 1, 2, 3
(Seite 3) bestimmt werden. Die Linie zur
Bestimmung der Differenz darf in den Nomo-
grammen die dunklen Felder nicht passieren.
Abb. 6
Wahl der Differenz
Um einen zweckmigen automatischen
Betrieb einer Anlage zu erreichen ist eine
angemessene Differenz erforderlich. Bei einer
zu kleinen Differenz ergeben sich kurze
Betriebszeiten mit dem Risiko der Pendelung,
wogegen bei einer zu groen Differenz
erhebliche Druckschwankungen auftreten.
Elektrischer Anschlu
Die KPS-Pressostate sind mit einer Kabel-
verschraubung Pg 13,5 ausgerstet, die fr
Kabeldurchmesser von 5 bis 14 mm
verwendbar ist. Gem den Zulassungs-
bedingungen des GL ist jedoch eine spezielle
Schiffskabelverschraubung vorgeschrieben.
Die Kontaktfunktion geht aus Abb. 7 hervor.
Abb. 5
Montage
KPS-Pressostate sind mit einer 3 mm starken
Befestigungskonsole ausgerstet. Die
Gerte sollten niemals selbsttragend" nur
am Druckstutzen befestigt montiert werden.
Druckanschlu
Beim Anziehen oder Lockern der berwurf-
mutter der Druckleitung sollte immer zugleich
an den Schlsselflchen des Druckstutzens
gegengehalten werden.
Dampfanlagen
Es empfiehlt sich, zwischen Dampfraum und
Pressostat eine wassergefllte Rohrschleife
vorzusehen. Diese Rohrschleife verhindert
eine bermssige Erhitzung des Druck-
elements. Eine solche Schleife lt sich z.B.
aus 10 mm starkem Kupferrohr herstellen
(siehe Abb. 5).
Wassergefllte Anlagen
Wasser im Druckelement schadet an sich
nicht, jedoch besteht bei Frost die Gefahr
einer Beschdigung. Um dieses Risiko aus-
zuschlieen, kann man fr den Betrieb des
Gerts ein Luftkissen vorsehen.
Medienbestndigkeit
Eine bersicht ber medienberhrte Bauteile
und Werkstoffe finden Sie auf Seite 4. Fr das
Medium Meerwasser empfehlen wir die Typen
KPS 43, 45, 47.
Pulsationen
Wenn im Druckelement starke Pulsationen
auftreten z.B. in Sprinkleranlagen (Feuer-
schutz), Brennstoffsystemen fr Dieselmotoren
(Vordruckleitung) oder in hydraulischen
Systemen (Propelleranlagen) empfiehlt sich
die Verwendung der Typen KPS 43, 45, 47.
Das max. zulssige Pulsationsniveau betrgt
bei diesen Typen 120 bar.
1 Bereichsspindel
2 Bereichsskala
3 Differenzspindel
4 Differenzskala
5 Sperrschraube
Abb. 7
Datenblatt
IK.20.E6.03 7
I. Ein Warnsignal fr abfallenden Druck wird
bei dem eingestellten Bereichswert
ausgelst.
II. Ein Warnsignal fr steigenden Druck wird
bei dem eingestellten Bereichswert plus
der Differenz ausgelst.
Abb. 9
Abb. 10
Abb. 8
1. KPS 31
Die Kontakte 1-2 schlieen und 1-4 ffnen,
wenn der Druck unter den eingestellten
Bereichswert abfllt. Die Kontakte wechseln in
die Ausgangslage zurck, wenn der Druck
wieder auf den Bereichswert plus der Differenz
steigt (siehe Abb. 8).
Funktion
Skaleneinstellung
Mechanische Differenz
I. Ein Warnsignal fr steigenden Druck wird
bei dem eingestellten Bereichswert
ausgelst.
II. Ein Warnsignal fr abfallenden Druck wird
bei dem eingestellten Bereichswert minus
der Differenz ausgelst.
2. brige KPS Pressostate
wenn der Druck den eingestellten Bereichs-
wert berschreitet. Die Kontakte wechseln in
die Ausgangslage zurck, wenn der Druck
wieder auf den Bereichswert minus der
Differenz abfllt (siehe Abb. 9).
Skaleneinstellung
Mechanische Differenz
Beispiel 1
Gewnscht wird eine Warnung, wenn in einem
gegebenen Motor der Schmierldruck unter 0,8
bar zurckgeht. Die Warnung erfolgt durch
eine Signallampe.
Man whlt KPS 31 (Bereich 0 bis 2,5 bar). Der
niedrigste zulssige Schmierldruck von 0,8
bar wird mit Hilfe der Bereichsspindel ein-
gestellt. Die fest eingestellte Differenz betrgt
0,1 bar. Das bedeutet, da die Warnung so
lange andauert, bis der Druck auf 0,9 bar
steigt. Die Signallampe wird an die Klemmen 1
und 2 des Pressostats angeschlossen.
Beispiel 2
Gewnscht wird eine Warnung durch ein
akustisches Signal (Alarmglocke), wenn in
einem gegebenen Kessel der normale
Betriebsdruck von 9 bar auf 10 bar ansteigt.
Man whlt KPS 37 (Bereich 6 bis 18 bar). Der
Bereichswert des Pressostaten wird auf 10 bar,
die Differenz auf 1 bar eingestellt.
Die Alarmglocke wird an die Klemmen 1 und 4
angeschloen.
Beispiel 3
In einem Startluftbehlter wnscht man, den
Druck mit Hilfe eines von einem KPS
gesteuerten Kompressor so zu regeln, da
der Druck zwischen 30 und 36 bar zu liegen
kommt.
Man whlt 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. 10
entsprechend auf ca. 2 eingestelit.
Die gewnschte Startfunktion ergibt sich,
wenn man die Klemmen 1 und 2 miteinander
verbindet.
Datenblatt
8 IK.20.E6.03
KPS-Thermostate sind temperaturgesteuerte
Wechselschalter, deren Kontaktstellung von
der Fhlertemperatur und dem eingestellten
Skalenwert abhngt. Die in kompakter Bau-
weise konzipierten und dicht gekapselten
Gerte sind robust,sto- und erschtterungs-
Thermostate, Typ KPS
Einfhrung
Bei Bestellungen bitte Typ und Bestellnummer angeben.
KPS mit Fernfhler und
armiertem Kapillarrohr
KPS mit Fernfhler
KPS mit festem Fhler
sicher und sie gengen sowohl bei einer Innen-
als Auenmontage hohen Ansprchen. Die
Thermostate werden fr Regel-, Warn- und
Oberwachungsaufgaben an Dieselaggregaten,
Kompressoren, Kraftwerken und Schiffen
eingesetzt.
Technische Daten und
Bestellung
Bestell-Nr.
Eigen- Max. Geeignete Kap.
Regel- diff. Fhler- Fhlerhlsen- rohr- Typ
bereich einstellb./ temp. lnge (siehe lnge
fest auch Zubehr)
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 - - - 060L3141
1)
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 060L3139
1)
060L3140
1)
KPS 83
1)Thermostat mit max. Reset
Zulassungen
Det norske Veritas, Norwegen
American Bureau of Shipping
Lloyds Register of Shipping, England
F Germanischer Lloyd, BRD
Bureau Veritas, Frankreich
Umfat Thermostate und Pressostate
mit festem Fhler und Thermostate mit
armierten Kapillarrohr.
EN 60 947-4-1
EN 60 947-5-1
Schiffszulassungen
U Underwriters Laboratories Inc., USA
Registro Italiano Navale, Italien
P Polski Rejestr Statkw, Polen
MRS Maritime Register of Shipping,
Ruland
Nippon Kaiji Kyokai, Japan
Datenblatt
IK.20.E6.03 9
Kontaktsystem
Einpoliger Wechselkontakt (SPDT):
goldbeschichtete Silberkontakte.
Gleichstrom: 12 W, 220 V, DC-13 Siehe
Kurve Abb. 1.
Kontaktbelastung (Wechselstrom:)
Ohmsche Last: 10 A, 440 V, AC-1
Induktive Last: 16 A,440 V, AC-3
4 A, 440 V, AC-15
Startstrom max. 50 A (blockierter Lufer).
Umgebungstemperatur 40 bis +70 C
Erschtterungssicherheit
Vibrationsfestigkeit im Bereich 2-30 Hz
Amplitude 1,1 mm und 30-300 Hz, 4 G
Schutzart
IP 67 gem IEC 529 und DIN 40050.
Pressostatgehuse aus lackiertem Aluminium-
druckgu (GD-AISi 12). Deckel mit vier Schrauben
befestigt. Bei einer Demontage ist der Deckel durch
eine Schlaufe gesichert. Die Kapselung kann mit
Sicherungsdraht plombiert werden.
Kabeleingang:
Pg 13,5 fr Kabeldurchmesser von 5 bis 14 mm.
Identifikation
Die jeweilige Typenbezeichnung und Bestell-
nummer ist seitlich am Gert eingeprgt.
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.
Zubehr: Fhlerhlsen fr Fhler- A Gewinde Best. Nr. Fuhler- A Gewinde Best. Nr.
KPS-Thermostate hlsen mm B hlsen mm B
Messing 65
1
/2 NPT 060L3265
75
1
/2 NPT 060L3264 Stahl 18/8 75 G
1
/2 A 060L3267
75 G
1
/2 A 060L3262
Messing 75 G
3
/4 A 060L3266
75 G
1
/2 A (ISO 228/1) 060L3281
75 G
3
/4 A (ISO 228/1) 060L3404
110
1
/2 NPT 060L3270 Stahl 18/8 110 G
1
/2 A 060L3268
110 G
1
/2 A 060L3271 110
1
/2 NPT 060L3270
Messing
110 G
1
/2 A (ISO 228/1) 060L3406
110 G
3
/4 A (ISO 228/1) 060L3403
160 G
1
/2 A 060L3263 Stahl 18/8 160 G
1
/2 A 060L3269
Messing 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 060L3237
Messing 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 Gert Best. Nr.
Spannband Fr KPS-Thermostat mit Fernfhler (L = 392 mm) X 017-4204
Fr KPS-Thermostate mit Fhler in Fhlerhlse.
Wrmeleit-
Zur besseren Wrmebertragung zwischen Fhler und Hlse. Nach
paste
Anwendungsbereich fr Paste: Bedarf 41E0110
(Tube mit 4,5 cm
3
)
-20 C bis +150 C, kurzfristig bis 220 C.
Wird ohne Schlitzschraube,
Dichtung und Unterleg-
scheiben geliefert
Abb. 1. d.c.-Belastung
Kurve A zeigt die maximale Belastung.
Die schraffierte Flche B: Zulssige
Belastung des Goldbelags der Kontakte.
Datenblatt
10 IK.20.E6.03
Mabilder und Gewichte
Montage Anordnung des Gerts:
Thermostate KPS knnen von der Konstruktion
her den allgemein auftretenden Erschtte-
rungen z.B. auf Schiffen, an Kompressoren
oder greren Maschinenanlagen wider-
stehen. Die Montage kann entweder mit Hilfe
der Konsole direkt an einer Wand, einem
Schott u. dergl. (Thermostate mit Fernfhler)
oder auch selbsttragend auf einer Fhlerhlse
(Thermo-state mit festem Fhler) erfolgen.
Medienbestndigkeit
Materialspezifikationen fr Fhlerhlsen:
Fhlerhlse aus Messing
Rohr aus Ms 72 gem DIN 17660, Gewinde-
stck aus So Ms 58 Pb gem DIN 17661.
Fhlerhlse aus rostfreiem Stahl 18/8
Materialbezeichnung 1.4305 gem DIN
17440.
Fhleranordnung
Der Fhler sollte mglichst so angeordnet
werden, da seine Lngsachse rechtwinklig zur
Strmungsrichtung verluft. Der aktive Teil des
Fhlers betrgt bei Gerten mit angebautem
Fhler und mit 2 m Kapillarrohr 13 mm x 50
mm. Bei den brigen Thermostaten (5 m und
8 m Kapillarrohr) betrgt der aktive Fhlerteil
70 mm.
Medienverhalten
Die schnellste Reaktion ergibt sich bei einem
Medium mit groer spezifischer Wrme und
hoher Wrmeleitfhigkeit. Daher ist es falls
man hinsichtlich der Medienwahl frei ist
vorteilhaft, ein Medium zu whlen, das diese
Voraussetzungen erfllt. Auch ist die
Abb. 3
Strmungsgeschwindigkeit des betreffenden
Mediums von Bedeutung. (Die optimale
Strmungsgeschwindigkeit fr Flssigkeiten
betrgt ca. 0,3 m/s). Zulssiger Mediendruck:
Siehe Abb. 2.
Abb. 2. Zulssige Mediendruckwerte gegen
Fhlerhlsen als Funktion der Temperatur
Einstellung
Gehusedeckel entfernen, Sperrschraube 5
Abb. 3 lockern und danach den Bereich durch
Bettigung der Spindel 1 und Ablesen der
Skala 2 einstellen.
Bei Gerten mit einstellbarer Differenz wird
diese durch Bettigung der Spindel 3 und
Ablesen der Skala 4 eingestellt.
1. Bereichs-
spindel
2. Bereichs-
skala
3. Differenz-
spindel
4. Differenz-
skala
5. Sperr-
schraube
KPS mit Fernfhler und armiertem
Kapillarrohr
Gewicht: ca 1.4 kg
(mit 2 m armiertem Kapillarrohr)
KPS mit festem Fhler
Gewicht: ca 1.0 kg
KPS mit Femfhler
Gewicht: ca 1.2 kg
(mit 2 m normalem Kapillarrohr)
Nichtrostender
Stahl
Messing
Datenblatt
IK.20.E6.03 11
Elektrischer Anschlu
KPS-Thermostate sind mit einer Pg 13,5
Kabelverschraubung versehen, die fr Kabel-
durchmesser von 5 bis 14 mm verwendbar ist.
Nach den Zulassungsbedingungen des GL ist
jedoch eine spezielle Schiffskabel-
verschraubung vorgeschrieben. Die
Kontaktfunktion geht aus Abb. 5 hervor.
Abb. 4
Einstellungsbeispiele Beispiel 1
Dieselmotor mit einer Khlwassertemperatur
von 85 C (Normalzustand). Gewnscht wird
ein Warnsignal, sobald die Khlwasser-
temperatur 95 C berschreitet. Zu whlen wre
ein Thermostat KPS 80 (Bereich 70 bis 120C)
Einstellung der Hauptspindel: 95 C
Einstellung der Differenzspindel: 5 C
Die gewnschte Warnfunktion ergibt sich, wenn
man die Klemmen 1-4 verbindet.
Nach einer gewissen Betriebsdauer des
Systems ist zu berprfen, inwieweit die
Betriebsdifferenz den Gegebenheiten
entspricht und ob eventuell eine Korrektur
vorzunehmen ist.
Beispiel 2
Zu ermitteln ist die notwendige Skalenkorrektur
fr einen KPS 80, der bei einer Umgebungs-
temperatur von 50 C auf 95 C eingestellt ist.
Die relative Skaleneinstellung Z wird nach
folgender Formel bestimmt:
Einstellwert min. Skalenwert
Max. Skalenwert min Relative Skalenwert
Relative Skaleneinstellung:
95 70
100 = 50%
120 70
Faktor fr Skalenabweichung (gem Abb. 4)
Z 0.7
Korrekturfaktor 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 Ceinzustellen
Skalenkorrektur
Die Fhler der KPS-Thermostate enthalten eine
sogenannte Adsorptionsfllung und knnen somit
ohne Beeintrchtigung ihrer Funktion wrmer oder
klter als der brige Teil des thermostatischen
Elements (Wellrohr und Kapillarrohr) angeordnet
werden. Eine solche Fllung ist zum Teil
nderungen der Wellrohr- und Kapillarrohr-
temperatur gegenber empfindlich, ein Umstand,
der aber unter normalen Verhltnissen ohne
Bedeutung ist.
Wenn dagegen die Thermostate bei extremen
Umgebungstemperaturen eingesetzt werden, so
ergeben sich Skalenabweichungen, die man wie
unten angegeben ausgleichen kann:
Skalenkorrektur = Z a
Z ermittelt man mit Hilfe der Abb. 4, whrend a
die Bezeichnung des Korrekturfaktors gem
nachstehender Tabelle ist. Siehe Beispiel.
Korrekturfaktor a
Regel- fr Thermostate
Typ bereich mit mit mit
festem 2 u. 5 m 8 m
C Fhler 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
Relative
Skalen-
einstel-
lung in %
100 = %
Faktor fr
Skalenabweichung
Die in Katalogen, Prospekten und anderen schriftlichen Unterlagen, wie z.B. Zeichnungen und Vorschlgen enthaltenen Angaben und technischen Daten sind vom Kufer vor bernahme
und Anwendung zu prfen. Der Kufer kann aus diesen Unterlagen und zustzlichen Diensten keinerlei Ansprche gegenber Danfoss oder Danfoss-Mitarbeitern ableiten, es sei denn, da
diese vorstzlich oder grob fahrlssig gehandelt haben. Danfoss behlt sich das Recht vor, ohne vorherige Bekanntmachung im Rahmen des Angemessenen und Zumutbaren nderungen
an ihren Produkten auch an bereits in Auftrag genommenen vorzunehmen. Alle in dieser Publikation enthaltenen Warenzeichen sind Eigentum der jeweiligen Firmen. Danfoss und das
Danfoss-Logo sind Warenzeichen der Danfoss A/S. Alle Rechte vorbehalten.
Danfoss
Wrme- und
Kltetechnik GmbH
Postfach 1261
63130 Heusenstamm
Tel.: (06104) 698-0
Telefax: (06104) 698-409
IK.20.E6.03 12
Wahl der Differenz
Um einen zweckmigen automatischen
Betrieb der Anlage zu erreichen, ist eine ange-
messene Differenz erforderlich. Bei einer zu
kleinen Differenz ergeben sich kurze Betriebs-
zeiten mit dem Risiko der Pendelung, wogegen
bei einer zu groen Differenz erhebliche
Temperaturschwankungen auftreten.
Differenzbegriffe
Als mechanische Differenz (Eigendifferenz)
bezeichnet man den an der Differenzspindel
eingestellten Wert. Dagegen nennt man die
Differenz, mit der die Anlage arbeitet, die
thermische Differenz (Betriebsdifferenz).
Funktion Die thermische Differenz ist stets grer als
die mechanische Differenz und ist von drei
Faktoren abhngig:
1) Strmungsgeschwindigkeit des Mediums,
2) nderungsgeschwindigkeit der Medien-
temperatur und
3) Wrmebertragung auf den Fhler.
Thermostatfunktion
sobald die Temperatur ber den auf der Skala
eingestellten Wert (Sollwert) ansteigt. Die
Kontakte gehen wieder in ihre Ausgangslage
zurck, wenn die Temperatur auf einen dem
Sollwert minus der Differenz entsprechenden
Wert abfllt. Siehe Abb. 6.
Danfoss A/S AG-SP. kaa 01-97
I. Ein Warnsignal fr steigende
Temperatur wird beim Bereichs-
einstellwert ausgelst.
II. Ein Warnsignal fr abfallende
Temperatur wird beim Bereichs-
einstellwert minus der Differenz
ausgelst.
Abb. 6
Mechanische
Differenz
Skaleneinstellung
Datenblatt
STWE
Reibschluverbindungen
Ausgabe
EDITION
Schw.
HSD 620-22
Schrumpfscheibe
Typ HSD Baureihe 22 16.11.00
STWE Postfach 800557 ( (02324) *394-0
GmbH & Co. KG D-45505 Hattingen Telefax (02324) 39430
HSD 620-22x620
Spannschrauben: 28x M30, DIN 933 10.9
max. Schraubenanzugsmoment: 1.640 Nm
D = 970 mm
l = 254 mm
H = 286 mm
A = 706 mm
d
1
= 630 mm
e = 29 mm
d = 620 mm
H8
/
f7
d
w
= 520 mm
H7
/
h6
Max. bertragbares Drehmoment M
T
= 3.169 kNm (
w
= 0,15)
H
D
A
d dw
l e
d1
Mounting and Removal Instructions
for Shrink Discs
Mounting
The shrink discs are supplied ready to be installed. Therefore they should not be dismantled prior to
employing 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 it
is 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 be
dangerous and result in injury.
2. Should the outer ring not-self release from the inner ring, this can be assisted by removing those
locking bolts adjacent to the tapped holes provided for jacking purposes and screwing them into
these tapped holes. The jacking procedure must continue until release of the outer ring is
achieved.
3. Dismount shaft or draw off hub. Remove rust which may have formed on the shaft in front of the
hub.
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 = 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 Klber Lubric (powder-spray)
Molykote G Rapid Spray or paste made by Unimoly
P5 Powder made by Klber Lubric Dow Corning

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