Elecon-

hydrokinetinc fluid coupling

traction type:
instructions for
installation
and maintenance.
Elecon-
hydrokinetinc fluid coupling
traction type:
instructions for
installation
and maintenance.

SIZE:..........................................................................................................................................................
TYPE:.........................................................................................................................................................
MOTOR:.......................................................................................................kW at.....................r.p.m.
COUPLING SERIAL NUMBER:........................................................................................................
OIL FILL:......................................................................................................................................litres
FILL ANGLE:.......................................................................................................................................
APPLICATION:.......................................................................................................................................

N.B. These instructions are intended primarily for

staff carrying out installation and maintenance of
the coupling unit.
It is imperative therefore to provide each mechanic
with a copy. Further copies, can be supplied on
request.
Should any questions remain outstanding after
consultatioin of this brochure, please contact us
immediately and one of our specialists will provide
you with further information.
CONTENTS
1 DESCRIPTION 1
• 1.1 General 1
• 1.2 Construction and operation 1
• 1.3 Types of mounting 1
2 INSTALLATION 1
• 2.1 Installation 2
• 2.2 Alignment 3
• 2.2.1 General method of aligment
• 2.2.2 Flexible Couplings
• 2.2.3 Fluid Coupling-Puliey Aligment
• 2.3 Oil filling 6
• 2.3.2 Type of oil
• 2.3.2 Quantity of oil and filling angle
• 2.3.3 Fusible plug
3 MAINTENANCE 10
• 3.1 Serving
• 3.2 Troubleshooting
• 3.3 Removal of fluid coupling unit
• 3.4 Repairs
4 SPARES 12
• 4.1 Ordering Spares 12
• 4.2 Drawing 13
• 4.2.1 Sizes 270-660 XR
• 4.2.2 Sizes 185-270 RX, 320-584 RX
• 4.2.3 Sizes 185-235 PHR & PHM, 185-235 PHR & PHM (large bore)
• 4.2.4 Sizes 270-370 PHR & PHM, PHR & PHM Mounting
• 4.2.5 Sizes 420-584 PHR & PHM, PHR & PHM Mounting
• 4.3 Parts List 19
1 DESCRIPTION Hollow Shaft Coupling : XR MOUNTING

1.1 General This compact assembly permits the motor and reducer unit
Elecon Fluid Coupling operates on the hydrokinetic power and the driven machine to be coupled in-line by means of a
transmission principle:power is transmitted by means of a Fluid Coupling with a flexible coupling on the motor side.
fluid, there being no mechanical contact between the motor The coupling is supported in position by the input shaft of
and the driven machine. As such, it constitutes a safety the reduction gear or the machine.
feature protecting transmission components from damage
due to overload or shock. The fluid coupling permits the use
of a squirrel cage induction motor with the attendant advan-
tages of simplicity, ruggedness and low operating costs.
Torque transmitted is directly proportional to the amount of
fluid in the unit and hence it is very simple, by varying the
oilfill, to match the coupling to the exact requirements of the
driven machine.

1.2 Construction and operation

Elecon hydrokinetic Fluid Coupling comprises of three es-
sential components:
-the impeller (2) driven by the motor
-the runner (3) fitted on the output shaft
-the runner casing (4) which forms an oiltight assembly. It is
possible also to fit a delayed filling chamber (23) to this
assembly, communicating with the working ciruit by means
of calibrated nozzles and retaining part of the fluid when the
Fluid Coupling stops running. At motor switch-on, only the
fluid in the work circuit is active and the torque developed is
Solid Shaft Coupling : R MOUNTING
low. During the start-up phase, fluid in the delayed filling
chamber transfers progressively into the work circuit, increas- The coupling is fitted on the motor shaft and coupled to the
ing the amount of active fluid and hence the torque. driven machine by means of a flexible coupling mounted
The motor thus starts under minimum load and the driven between the Fluid Coupling output shaft and the input shaft
machine is brought up to speed smoothly. Different mountings of the machine.
are available, the type of coupling being chosen accordingly.

1.3 Types of Mounting

Pulley-type coupling: PH MOUNTING. This compact assem-
bly features a hydrokinetic Fluid Coupling combined with a
grooved pulley. The assembly is fitted on the motor shaft
and requires no aditional support other than of the motor.
2. INSTALLATION
2.1 Installation of Coupling
Elecon hydrokinetic Fluid Coupling is delivered with its runner shaft machined to match the driven machine or motor shaft
dimensions.
Installation operations:
1) Check that the shafts are dead-centred.
2) Fit the keys and grease the shaft.
3) Fit the coupling on the motor shaft or driven shaft, as required, by means of a threaded rod and a plate (Figure 1).
Ensure that the plate is in correct position on the hollow shaft and not on the delayed filling chamber, which would otherwise
suffer damage.

Fig 1

4) When the coupling is correctly in position, prevent any

lateral displacement by fitting the retaining plate, TREP
washer and lock nut (Figure 2).
5) For the XR mounting, fit the flexible coupling boss on the
motor shaft by means of a threaded rod and a plate (as
shown in Figure 1 for the traction coupling).
Check that the end of the motor shaft does not knock
against the traction coupling.

N.B. : The use of non-recommended equipment (eg, hammers, clamping plates, oxyhydrogen bumers, etc.) is liable to
damage the unit and may invalidate warranty claims.
2.2 Alignment
Correct alignment is essential for the correct functioning of the Fluid Coupling and the durability of the installation.

Alignment Procedure:
1) Once the driven machine is mounted in its correct posi-
tion, bolt it onto the bed-plate.
2) Fit the flexible components in the flexible coupling or the
pulley belts in the case of a PH coupling.
3) Place the electric motor close to the traction coupling in
approximately the correct position. For precise motor align-
ment, particularly with large motors, the use of adjust-
ment screws with brackets attached to the bed-plate (see-
Figure 3) is recommended.
Various possibilities exist for motor-Fluid Coupling alignmjent.

2.2.1 General method of alignment

In general, correct alignment requires that:
a) the two half-couplings must be perfectly parallel. No angle should be formed between them.
b) while remaining parallel, the two half-couplings must not be offset raadially to each other.
The first condition is met if a thickness guage or caliper gives a constant reading of ± 0.1 mm. between the two half-
couplings when the Fluid Coupling is rotated manually through 3600.
The second condition is met if a flat rule laid against the external diameters of the half-couplings is perfectly flush with the
surface of both.
Greater accuracy of alignment can be achieved by using a dial gauge.
After tightening the motor holding-down bolts and the flexible coupling flange bolts, re-check the alignment.
2.2.2 Flexible Couplings with size of fluid coupling.
Method of alignment, its values and tolerance are as per IS:2693

Size of Size of
Fluid Couling Flexible Coupling
320 FCF 6
370 FCF 7
420 FCF 9
480 FCF 10
584 FCF 13
660 FCF 14
760 FCF 16

See: General alignment method.

Size of Size of
Fluid Coupling Flexible Coupling
320 FCFB 6
370 FCFB 7
420 FCFB 9
480 FCFB 10
584 FCFB 13
660 FCFB 14
760 FCFB 16

See: General alignment method.

2.2.3 Fluid Coupling-Pulley algnment (Type PHR-PHM)

1) Fit the coupling on the motor shaft or driven shaft, as required, by means of
a threaded rod.

2) Fit the pulley belts (untensioned) by moving the two pulleys as close to-
gether as possible.

3) Ensure that the two pulleys are parellel by means of a wire or a rule.

4) Before tensioning the belts on the pulleys,trace two thin lines transversally
on the back of one of the inside belts. These marker lines should be as far
apart as possible.

Progressively tighten the pulley belts, after rotating them during several period
of one minute each. Between these periods, tighten the belts so as to increase
the length between the marker lines by the percentage listed below:

Transmission UNIFORM motor or IRREGULAR motor or

characteristics resistive torque resistive torque
Small diameter pulleys 0.6% 0.8%
short distance between
centres(E<D+d)
Medium or large diameter 0.8% 1%
pulleys Medium or large
distance between centres

E=distance between pulley centres; D and d=pulley diameters

After 24 hours operating, check the transmission and re-tighten the pulley belts,
if necessary.

For example:an initial distance of 1000 mm between the 2 marker lines will be
increased by the tension to 1006 mm (0.6%) or 1008 mm (0.8%).
2.3 Oilfilling
The choice of coupling size having been made in accordance with the rotating speed and the power transmission required,
the oilfilling for the traction coupling will be determined by:
-the power actually transmitted to the machine.
-the required starting torque.
The maximum allowable oilfill amounts to approximately 80% of the total capacity of the Fluid Coupling. This level should
never be exceeded since overfilling may cause overpressure inside the coupling and damage to the seals.
2.3.1 Types of oil
During normal operating conditions, the fluid used (usually mineral oil) should meet the following requirements:
Density at 150 C 0.873-0.879
Engler Viscosity at 500 C 2.9 to3
Flash point 0C. 210
Aniline point 105 to 108
Pour point -300
Viscosity indext ≥ 105

The oild used should be antioxydant and anti-foaming.

Correspondence tables of oils, recommended for our traction couplings:(Viscosity as per ISO 3448)

Make Oil type

Recommeded Possible variants
Bharat Bharat Hydrol 46 Bharat Hydrol 32
Petroleum
Castrol Castrol Hyspin VG 46 Castrol Hyspin VG 32
Indian Oil Servosystem HLP 46 Servosystem HLP 32

2.3.2 Determination of the initial oil filling Oil Change

To determine the amount of oil required:
Recommended every 8000 hours of working or every two
USE years.
Table 3.a for CD (without delayed filling chamber)
Table 3.b for CDR (with delayed filling chamber)
Table 3.c for CDRP (with extended delayed filing chamber)
- Calculate the nominal trorque co-officient, Kn, us-
ing the following formula:
Kn = P
X
Where P = motor power or transmitted power in Kw
X = value taken from table 1, appropriate to the
coupling size and motor speed.

The co-efficient Kn corresponds to the nominal full load torque.

Calculat the co-efficient Km corresponding to the starting

(or stalling) torque as shown in the following example:
Table 1
VALUE of X
(for Type CD, CDR, CDRP)

Fluid Size
*185 *235 * 270 320 370 420 480 584 660 760 870

Coupling Outside 225 275 315 365 425 475 550 670 760 870 995
Diameter Dmm
750 0.06 0.2 0.38 0.90 1.90 3.57 6.85 18.7 34.4 70 135
900 0.10 034 0.66 1.56 3.27 6.17 11.9 32.3 59.4 120 235
1000 0.14 0.47 0.91 2.15 4.48 8.45 16.3 44.2 81.5 165 320
1200 0.25 0.82 1.60 3.75 7.50 14.70 28.5 77.3 142 280 550
1500 0.49 1.62 3.14 7.40 15.50 29.0 56.2 153 280 (565) (1115)
1800 0.85 2.80 5.43 12.8 26.80 50.1 97.1 264 (484) - -
3000 3.91 12.9 25.20 59.3 123 - - - - - -

*Note : For size 185, 235 & 270 coup. type CDR & CDRP are not applicable.

Table 2

FILLING ANGLE α0

Table 2.a Table 2.b Table 2.c

Coupling Type CD CDR CDRP
Co-efficient Km Kn Km Kn Km Kn
50 5.6 2.4 5.7 2.7
55 5.1 2.1 5.2 2.5
FILLING ANGLE α 0

60 4.5 1.9 4.7 2.2 4.7 2.8

65 3.65 1.7 4.1 2.1 4.1 2.7
70 2.66 1.6 3.2 2 3.2 2.5
75 2 1.3 2.8 1.8 2.8 2.2
80 1.5 0.8 2.4 1.7 2.4 2.1
85 1.3 0.6 2.1 1.4 2.1 2
90 1 0.4 1.8 1.2 1.6 1.8
95 0.8 0.3 1.2 0.9 1.2 1.5
100 0.7 0.2 0.96 0.7 0.95 1.3
 Table 3.a
Coupling Type CD (without Delayed dilling chamber)

Size 185 235 270 320 370 420 480 584 660
50 1 1.90 2.60 4.20 7.10 10.05 15 26.55 44.50
55 0.97 1.86 2.45 4 6.90 9.50 14.30 26.60 42.60
60 0.93 1.80 2.30 3.80 6.50 8.90 13.60 24.30 40.60

FILLING ANGLE α 0
65 0.88 1.70 2.20 3.60 6 8.40 12.80 23 38.20
70 0.82 1.58 2.00 3.30 5.70 7.80 12 21.40 35.80
75 0.76 1.50 1.90 3.10 6.20 7.20 11.20 20 33.40
80 0.70 1.39 1.80 2.90 4.80 6.70 10.20 18.40 31
85 0.64 1.27 1.70 2.65 4.40 6.30 9.30 16.80 28.60
90 0.57 1.14 1.55 2.40 4 5.70 8.50 15.30 26.30
95 0.52 1.02 1.40 2.25 3.70 5 7.80 14 24
100 0.46 0.90 1.30 2.10 3.40 4.60 7.20 13 22

Table 3.b Table 3c

Coupling Type CDR (with Delayed filling chamber) CDRP (with Extralarge delayed filling chamber)
Size 320 370 420 480 584 660 760 870 370 420 480 584 660 760 870
50 5.20 9 12.50 20 34.10 52 75 111 10.90 15.20 22 36.50 59.50 90 136
55 5 8.60 12.10 18.90 32.70 50.20 71 105 10.30 14.80 21.10 35.10 57.80 85 129
60 4.70 8.20 11.30 17.90 31.20 47.80 67 99 10 14.20 20.20 33.60 55.10 80 122
FILLING ANGLE α 0

65 4.40 7.60 11 16.60 29.20 45 62 93 9.20 13.65 19.10 31.80 51.80 75 114
70 4 7 10 15.30 27.20 42 57 86 8.30 13 18.10 30 48.20 68 106
75 3.70 6.50 9.40 14.30 25 39 53 79 7.80 11.90 16.90 28.20 44.20 63 96
80 3.30 5.90 8.60 13.30 22.80 36 49 73 7 10.80 15.70 26.20 41 58 88
85 3.10 5.60 8.10 12.10 20.90 33 46 68 6.6 0 9.70 14.50 24.20 37.40 54 81
90 2.90 5 7.25 10.90 19 30.20 42 63 6 8.60 13.20 22.20 34.10 49 75
95 2.70 4.80 6.50 9.60 17.50 27.60 38 58 5.90 7.30 12 20 31.20 44 69
100 2.50 4.20 5.90 8.40 15.90 25.30 34 53 6 6.50 10.70 17.80 28.60 40 62

Approximate equivalent oil volume in litres at 200 C

Checking the oil fill
1) Place filling plug in vertical position and remove.
2) Rotate the coupling clowly until the oil just comes up to
the filling hole.
This position must match the angle from top-dead-centre
calculated by the method given above.
3) If necessary, remove or add some oil.
4) Replace filling plug and tighten.

2.3.3 Fusible plug

A fusible plug (22) is fitted at one of the filling holes, for the
purpose of preventing overheating of the coupling in the event
of a prolonged stall or failure of the motor thermal relay. After
removing the cause of the stall, a new fusible plug must be
fitted and the coupling filled with clean oil as [per specifica-
tions.
For industrial applications, the maximum temperature is 140
(fusible p[lug marked number 1). At that termperature, thye fus-
ible plug melts, allowing the oil in the coupling to drain off and
removing the load from the motor. For applications with Diesel
or Petrol engines, or in certain specific applications in industry,
fusible plugs with a set melting point of 2000 are used (fusible
plugs marked number 2).

Safety features
Oil losses can be prevented by using a thermal trip plug fitted
instead and in the place of the fusible plug. This device actu-
ates a motor cut-out system or triggers a warming signal in the
event of the oil in the coupling reaching the set maximum tem-
perature. In the event of activation, re-set the motor cut-out
switch and fit a new thermal trip plug.
It is preferable to refill the coupling with cold fluid to acoid down-
time while the original cluid cools down.
3. MAINTENANCE If the oil appears dark in colour and emits a semll of burning,
this is due to overheating. The oil is liable to oxidize or acidify
3.1 Servicing and must be replaced immediately. Coupling temperature
depends on the local operating conditions (frequency of start-
Elecon Fluid Coupling requires virtually no servicing since ups, ambient temperatur,ect). But in no case should it ex-
there are no mechanical components in contact with each ceed 80C. during normal service.
other (other than bearings and seals). Bearings are amply
dimensioned. b) Checking alignment

Seals are custom-built for our equipment and can withstand In the event of misalignment occuring during service, this
pressure of three bars. They are made of viton, ie, a material causes wear to the components of the flexible coupling It is
capable of withstanding cinstant temperatures of up to 200 recommended to replace them and correct the alignment.
C. c) Replacing fusible plugs
Nonetheless, periodic checks of the seals and the coupling If the fusible plug has melted due to an overload or stall in
alignhment are necessary. A programme of three-monthly driven machine, it must be replaced by a new Elecon-Sime
checks, for example, may well prove suitable, depending on fusible plug and coupling re-rilleg with clean oil.
the duration and type of service involved.
Warning :
a) Checking seals and oil level
Fusible plug should never be replaced by solid plugs or ordi-
All coupling undergo checks for all seals before leaving the nary solder. This would demage the Fluid Coupling and in-
factory. validate warranty claims.
The oil tightness of the filling plug and the Fluid Coupling
can be checked by holding a clean sheet of paper some 10
cm from the coupling-any oil leaks will be shown up by this
paper test.

3.2 Troubleshooting
1. Driven shaft fails to reach speed.
a) Insufficient oil. Check oilfill, as per 2.3.2
b) Coupling seals not fully oiltight. Check tightness of seals, as per 3.1
c) Faulty motor or motor coupling. Check motor:for electric motor, check speed, power consuption,etc., for
diesel/petrol engine, check fuel injection setting, etc.
2. The fusible plugs melt.
a) Insufficient oil. Check the oilfill, as per 2.3.2
b) Coupling seals not fuly oiltight. Check tightness of seals, as per 3.1
c) The drivn machine stalls or jams. Check machine and remove cause of stall.
d) Excessive power consumption of the Veryfy power consuption by means of a double wattmeter.
driven machine.
3. Abnormal vibrations/noise levels
a) Incorrect algnment. Check alignment, as per 2.2, and correct, if necessary.
b) Damage to bearings. Check the coupling. Locate noise and vibration sources by ear or by
means of sound measurement instruments.
c) Nut and bolt assemblies loose. Check that holding-down bolts on motor, bed-plate and driven machine
are correctly tightened.
d) Undue vibration of the assembly. After checking points a,b and c, locate source of vibrations and elimi-
nate cause.
3.3 Removal of Fluid Coupling Unit

To remove the Fluid Coupling (XR and R mounting), the

electric motor must be detached. After removing lock
nuts and washers, use the special forcing-off bolt (48) to
remove the coupling, having previously smeared the
thread and end of the bolt with lubricant (oil or grease).

The special forcing-off bolt is supplied only on request.

The same bolt can be used with the various XR and PH
mountings, and for several sizes of coupling, as shown
in the table below:

Fluid Coupling Forcing-off bolt reference Thread

number
Sizes 270-320-370
Sizes 420-480-584-660

For Fluid Couplings of the 185 and 235 type, the coupling shaft bore (tolerance F8) allows installation and removal to be
carried out manually and this method must be employed.

3.4 Repairs

Whenever possible, repairs should be carried out in the workshops. All repairs must be done by qualified personnel working
in a clean place.

Dismantling:
First remove the delayed filling chamber when fitted (23) byundoing the securing bolts (25). To disconnect the chamber from
its casing, insert and tighten the two bolts (25) in the two specially provided forcing-off holes. Note relative position of the
balance weights and remove bolts(18). By means of the forcing-off holes drilled in the impeller flange, disconnect the
impeller from its casing (4).
Then disconnect the casing (4) from the shaft/runner assembly (3). In general, bearings(8) and (9) remain in position on the
shaft. If duie for replacement, they can be removed by means of bearing puller. Remove seals (7) and (29) taking great care
not to damage the polished sealing surfaces on the shafts.
Reassembly is carried out by reversing the order of operations. Certain precaustions must be taken:
10) Mating surfaces perticularly between chamber and casing and between casing and impeller, must be throughly cleaned
with trichlorethylene to remove all traces of sealing compound. For perfect seals, CURTYLON compound is recom-
mended.
20) Check that there is no damage to the polished section of the shaft where seal rings (7) and (29) are fitted.
30) Fit the seal rings (7) and (29) in position by means of a press-fitting tool.
0
4) Fill the space between the two seal ring rims with grase.
50) During the assembly of the impeller (2) and the casing (4), the coupling serial numbers stamped on each of these
components should be aligned for purpose of balancing.
N.B.: For traction coupling 420,480 and 584 PH, apply grease (SKF 65-2 or 65-3) to the needle bearing (50) and thespace
between seal ring (52) and baffle (58).
4.SPARES
4.1 Ordering spares
10) Consult general diagram for your coupling to find the
reference number of the part required,eg. ball bearing,
no. 8.

20) Find the size and serial number of the traction cou-
pling for which the spare is required. The serial number
is stamped on the outside of the coupling, eg. coupling
420, number 55077.

30) Order the spare by quoting as follows : Ball Bearing,

reference

No. 8 for Coupling No. 55077.

4.2 Drawings

4.2.1 SIZES : 270-660 XR

N.B. : Size 270 has no delayed filling chamber(23)
4.2.2 SIZES : 185-270 R

SIZES : 320-584 R
4.2.3 SIZES : 185-235 PHR AND PHM

SIZES : 185-235 PHR AND PHM

(LARGE BORE)
4.2.4 SIZES : 270-370 PHR AND PHM
PHR Mounting

PHR Mounting
4.2.5 SIZES : 420-584 PHR AND PHM
PHR Mounting

PHR Mounting
FCF Coupling

FCFB Coupling
l 4.3 Part List
Ref Name of part

1 Shaft
2 Impeller
3 Runner
4 Casing
4B Casing
4C
4D R Mounting Casing
5 Motor baffle
6 Runner Baffle (PHR)
6(B) Runner Ballle (PHM)
7 Shaft seal
8 Bearing
9 Bearing
10 Flexible ring or collar
11 Flexible ring or collar
12 Flexible ring or collar
13 Filling plug
14 Fibre Washer
15 Stop ring
16 Stop ring
17 Baffle retaining bolt
18 Casing bolt
19 Nut
20 Lock washer
22 Fusible plug
23 Delayed filling chamber
23F FLEX delayed filling chamber
24 Lock washer
25 Delayed filling chamber bolt
26 Runner bolt
26E Circuit bolt
27 Lock washer
28 Nut
29 Shaft seal ring
30 Key
40 Retaining bolt assembly
50 Bearing
51 Stop segment
52 Shaft seal ring
53 Internal circlip
54 Washer
55 Nut
56 Stud
57 Pulley bolt
58 Grease reservoir baffle
70 Grooved pulley
80
81
92 Flange
93 Driving boss
94 Driving boss bolt
95 Washer
100
110
111
120
121
130
131
140
141
150 PERIFLEX coupling
151 Rubber element
152 Driving half
153 Flange half
154 Rubber bush
155 Pin with hex nut & washer
156 Brake drum half
 Manufactured by :

ELECON ENGINEERING CO. LTD.

POST BOX # 6, VALLABH VIDYANAGAR 388 120, GUJARAT, INDIA
Tel. : +91 (2692) 36513, 32890 - Fax : + 91 (2692) 36527
E-mail : [email protected]. Web Site : http://www.Elecon.co.in
ALWAYS A STEP AHEAD IN TECHNOLOGY