Voith BTS-Ex User manual

Installation and Operating Manual
(Translation of the original installation and operating manual)
BTS-Ex
Non-contacting Thermal Switch Unit
for limiting the maximum surface
temperature on Voith Turbo Couplings
Version 7, 2020-07-15
3626-019600ex en, Protection Class 0: public

Installation and Operating Manual / Version 7 / 3626-019600ex en / Protection class
0: public / 2020-07-15
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BTS
-Ex, non-contacting thermal switch unit
Contact
Contact
Voith Group
St. Pöltener Str. 43
89522 Heidenheim, GERMANY
Telefon: + 49 7951 32 1666
E
-Mail: [e-mail]
Internet
: www.voith.com/fluid-couplings
If you have questions regarding the
product, please contact the Voith
Service
stating the serial number (see
nameplate).
3626
-019600ex en
This document describes the state of de-
sign of the product at the time of the
editorial deadline on 2020
-07-15.
Copyright © by
J.M. Voith SE & Co. KG
This document is protected by
copy
right.
It must not be translated, duplicated
(mechanically or elec
tron
ically) in whole
or in part, nor passed on to third parties
without the publisher's written approval.

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BTS-Ex, non-contacting thermal switch unit
Contents
Contents
1Possible Applications, BTS-Ex Characteristics 5
1.1 Use as safety device in potentially explosive atmospheres 5
1.2 Special conditions for the use in potentially explosive
atmospheres and as safety device in potentially explosive
atmospheres 7
1.3 Declaration of conformity 8
2Function of BTS-Ex 9
2.1 Switching element 10
2.2 Initiator 10
2.3 Evaluator 10
2.4 Interaction of BTS-Ex components 11
3Technical Data 13
3.1 Switching element 13
3.2 Initiator, mounting flange 14
3.3 Evaluator 14
4User Information 15
5Safety 17
5.1 Safety information 17
5.1.1 Structure of safety information 17
5.1.2 Definition of safety symbols 18
5.2 Intended use 18
5.3 Unintended use 18
5.4 General information as to dangerous situations 19
5.5 Remaining risks 22
5.6 What to do in case of accidents 22
5.7 Information with regard to operation 22
5.8 Qualification of staff 23
5.9 Product monitoring 24
5.10 Nameplate 24

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BTS
-Ex, non-contacting thermal switch unit
Contents
4
6Installation 25
6.1 As delivered condition 25
6.2 Scope of supply 26
6.3 Mounting - switching element and initiator 26
6.4 Mounting, connection - evaluator 29
7Display and Setting of Evaluator 31
7.1 Design 31
7.2 Setting of DIP switches S1 and S2 (cutoff frequency) 31
7.3 Setting the S3 DIP switch - (start-up bypass) 32
7.4 Setting of start-up bypass time 32
8Commissioning 34
9Maintenance, Servicing 35
9.1 Outside cleaning 37
10 Disposal 38
11 Malfunctions - Remedial Actions, Troubleshooting 39
12 Queries, Orders Placed for Field Service Engineers and
Spare Parts 42
13 Spare Parts Information 43
13.1 Switching elements 43
13.2 Initiator, mounting flange 44
13.3 Evaluator 44
14 Annex 45
14.1 EU Declaration of Conformity 45
14.2 Initiator NJ10-22-N-E93-Y106925 46
14.3 Initiator NJ10-22-N-E93-Y30627 47
14.4 Initiator NJ10-22-N-E93-Y30629 48
14.5 Initiator NJ10-22-N-E93-Y245590 49
14.6 Initiator NJ10-22-N-E93-Y246868 50
14.7 Initiator NJ10-22-N-E93-Y246869 51
14.8 Evaluator KFD2-SR2-Ex2.W.SM 52

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Possible Applications, BTS-Ex Characteristics
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1 Possible Applications, BTS-Ex
Characteristics
The non-contacting thermal switch unit (BTS-Ex) is a monitoring system for Voith
turbo couplings.
– The BTS-Ex provides easy monitoring of the turbo coupling temperature.
– In case of excess temperature, dependent on the application,
- the operator can be warned,
- the drive motor shutdown can be initiated,
- the load on the driven machine can be reduced.
– If excess temperature is identified in time, the discharge or loss of coupling filling
through the fusible plugs can be avoided.
Downtimes are reduced.
– After the turbo coupling has cooled down, the BTS-Ex resets automatically.
– The BTS-Ex can be used for Voith turbo couplings from size 366.
1.1 Use as safety device in potentially explosive
atmospheres
The BTS-Ex can be used in potentially explosive atmospheres as safety device to limit
the maximum permissible surface temperature of the turbo coupling. An ignition
protection level IPL1 (SIL 1) is reached in a low requirement rate.
WARNING
Explosion hazard
When the permissible surface temperature is exceeded, there is the risk of
explosion.
•
In case of excess
temperature, the drive motor has to be switched off within
the specified time (installation and operating manual of turbo coupling).
The following electrical equipment belongs to the whole system:
– Switching element (will be fixed to the turbo coupling)
– Initiator to evaluate the switching element
– Evaluator with safety-related function.

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-Ex, non-contacting thermal switch unit
Possible Applications, BTS-Ex Characteristics
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The safety devices will be installed into/fixed to a master machine. Depending on the
ingress protection level (IP), the interval for cleaning the operational equipment (dust
deposits) has to be defined.
Switching element and initiator may be used as follows:
– In Zone 2 (gas-Ex, Category 3G, EPL Gc) in Explosion Groups IIA and IIB
(initiator also IIC)
– In Zone 22 (dust-Ex, Category 3D, EPL DC) in Explosion Groups IIIA, IIIB and IIIC
– In Zone 1 (gas-Ex, Category 2 G, EPL Gb) in Explosion Groups IIA and IIB
(initiator also IIC)
– In Zone 21 (dust-Ex, Category 2D, EPL Db) in Explosion Groups IIIA, IIIB and IIIC
WARNING
Explosion hazard
In case of non
-compliance
with the conditions for use, there is the risk of
explosion.
•
In case of explosive dust atmospheres of Explosion Group IIIC, the product
may be used with organic dusts only.
It is only allowed to install the evaluator beyond potentially explosive atmospheres in
housings that comply with the IP category of environmental requirements or in
housings with own approval.
Qualification with regard to surface temperature depends on the ambient conditions; it
applies to T4...T3: T4 means that for all gases, vapors, mists with an ignition
temperature of > 135 °C, the equipment is not an ignition source.
In explosive dust atmospheres, the reference temperature T***°C (from 85 °C to 190
°C) is relevant for the further considerations with regard to safety distance to the
smoldering temperature.

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BTS-Ex, non-contacting thermal switch unit
Possible Applications, BTS-Ex Characteristics
1.2 Special conditions for the use in potentially explosive
atmospheres and as safety device in potentially
explosive atmospheres
The devices are only approved for proper and intended use in accordance with the
instructions. Contravention excludes any warranty and responsibility on the part of the
manufacturer!
– Only use accessories in potentially explosive atmospheres which satisfy all
requirements of European directives and national legislation.
– In case of explosive dust atmospheres of Explosion Group IIIC, the product may
be used with organic dusts only.
– It is imperative to comply with the ambient conditions as specified in this operating
manual.
– The provision of lightning protection measures have to be ensured by the
operator.
– Ensure that the fusible plugs required in addition are used on each turbo coupling
which is operated with this safety device.
– If the maximal permissible surface temperature of the turbo coupling is ensured by
this safety device, the type of protection "Protection by ignition source monitoring"
also applies to the turbo coupling.
– Voith Turbo has to determine the response temperature.
– The ambient temperatures of individual elements must not exceed the respective
limiting temperatures.
– Mechanical damage caused by ice formation must be reliably excluded.
– Locks need to be re-attached after opening and closing.
– Operation of the safety device is only allowed with undamaged housings and
lines.
– Make sure to satisfy electromagnetic compatibility when installing the system.
– On installation, it is vital to observe the nationally applicable provisions governing
installation of equipment, such as EN 60079-14, EN 1127-1 and EN 1127-2.
– It is mandatory to provide an equipotential bonding. Compliance with provisions
governing the installations into plants in the country of use must to be ensured
(e.g. VDE 0100, part 540, IEC 364-5-54).
– Avoid electrostatic charging.
– To ensure the discharge of electrostatic charging, please observe the national
regulations.
•Non-conductive parts must not exceed a surface of 100 cm² in IIB.
•It is not allowed to use the BTS-Ex in equipment with electrical corrosion
protection, or after consultation with the manufacturer and by taking special
measures only. It is not permitted to route compensation currents through the
construction.
– The evaluator is designed for use in Contamination Level 2, as per DIN EN 50178.
Protect the switching element and initiator against the ingress of liquids and/or
impurities, if required. This depends on the operating conditions, e.g. heavy dust
contamination or chemically aggressive fluids.
– For temperatures below -20 °C, install the initiators with mechanical protection.
Operating manual
of turbo coupling

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-Ex, non-contacting thermal switch unit
Possible Applications, BTS-Ex Characteristics
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– Keep a minimum distance of 3 mm between switching element and initiator (
Chapter 6.3).
– After switching off, it is mandatory to eliminate all errors/faults before re-starting or
switching on again the BTS-Ex.
– It is recommended designing the monitoring devices and monitoring circuits of the
shutdown chain at least as per PL c according to EN ISO 13849-1 or SIL 1
according to EN 61508 or EN 62061.
– In case of existing explosive atmosphere, it is not permitted so loosen seized parts
(caused e.g. by frost or corrosion) forcefully. Icing-up has to be avoided.
– The operator has to provide protective measures according to the explosion
protection document, e.g. protection against external impact energy.
– In order to ensure explosion protection, electrical equipment and mechanical
devices mounted in addition have to comply with the requirements of the zones
applying on the jobsite and shall be inspected separately by the person installing
the machine.
– Coatings / paintings are permissible up to a thickness of 0.2 mm in Explosion
Group IIC. In IIB / I, it is never allowed to exceed a thickness of 2 mm; if
necessary, a reduction of e.g. 0.5 to 1 mm has to be made dependent on the
quality of the coating / painting. Operators are not allowed to perform any
paintings.
1.3 Declaration of conformity
Annex (see declaration of conformity)

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BTS-Ex, non-contacting thermal switch unit
Function of BTS-Ex
2 Function of BTS-Ex
The non-contacting thermal switch unit (BTS-Ex) consists of three components:
– Switching element
– Initiator with mounting flange
– Evaluator
Fig. 1
Evaluator
a = 4 ± 1 mm
Turbo coupling
Initiator
Mounting flange
Switching element
a

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-Ex, non-contacting thermal switch unit
Function of BTS-Ex
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2.1 Switching element
The switching element is a passive component (ordinary electrical equipment). It is
inserted into the outer wheel or into the turbo coupling shell. The result is a thermal
contact between the switching element and the turbo coupling with the operating fluid.
A coil and a thermostatic switch are integrated in the switching element. The switching
point of the thermostatic switch corresponds to the response temperature of the
switching element.
Below the nominal response temperature, the thermostatic switch is closed and
bridges the coil. Above the nominal response temperature, the thermostatic switch
opens and interrupts the circuit. When the temperature decreases, the thermostatic
switch connects again the circuit. The BTS-Ex is again ready for service (it resets
automatically).
2.2 Initiator
The initiator has been designed as intrinsically safe, polarized two-wire sensor. It
works to the inductive sensor principle.
An electric oscillator is integrated in the initiator which produces a high-frequency
oscillation. The oscillator has an oscillating circuit as element determining the
frequency, comprising a coil and a capacitor.
The oscillating circuit coil is located in the sensor head. An electromagnetic alternating
field leaves the sensor head via this coil.
2.3 Evaluator
The evaluator is an electronic unit recording the electric pulses and evaluating the
period between the pulses (appropriate equipment with intrinsically safe circuit to the
explosive atmosphere).
The evaluation starts by switching on the supply voltage.
After starting the evaluation, monitoring of pulses must be interrupted for an
adjustable period of time (start-up bypass time).
A relay with changeover contact will be released if the number of pulses per unit of
time drops below a certain value.
Nominal response
temperature
Chapter 3.1

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BTS-Ex, non-contacting thermal switch unit
Function of BTS-Ex
2.4 Interaction of BTS-Ex components
Instead of a blind screw, the switching element is screwed into the turbo coupling. The
initiator with mounting flange is mounted parallel with the turbo coupling axis and is
connected to the evaluator.
The coil inside the switching element is coupled inductively with the coil inside the
initiator if the switching element is located in front of the initiator head. When the
thermostatic switch is closed, energy is transmitted from the initiator to the switching
element. The oscillator is attenuated and has a lower current consumption.
If the coupling temperature exceeds the response temperature of switching element,
the thermostatic switch will interrupt the circuit in the switching element. The switching
element can no longer attenuate the oscillator in the initiator.
The evaluator recognizes the attenuation of initiator due to the initiator current con-
sumption.
If the turbo coupling with screwed in switching element rotates, then the switching ele-
ment will permanently pass the initiator, thus permanently creating attenuation pulses.
Thus, permanently attenuation pulses are generated. The output relay in the evaluator
is energized.
In case of excess temperature, these attenuation pulses are not given, i.e. the cutoff
frequency set on the evaluator is not reached. The evaluator recognizes the missing
pulses, the output relay is de-energized.
Installation, position
Chapter 6.3
Cutoff frequency
Chapter 3.3

BTS
-Ex, non-contacting thermal switch unit
Function of BTS-Ex
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On startup of the turbo coupling, a start-up bypass time is set at the evaluator. As long
as the start-up bypass is active, the output relay remains energized.
After this set time, the speed of the turbo coupling with the switching element must
have exceeded the set cutoff frequency.
WARNING
Risk of personal injuries and damage to property
Following the shutdown, the control system has to be locked in a way that
prevents automatic re
-start.
•
Switch
off the unit in which the turbo coupling is installed and secure the
switch against inadvertent switch-on.
•
For all work performed on the turbo coupling and BTS-
Ex ensure that both
the drive motor and the driven machine have stopped running and that
unintended starting is absolutely impossible!
WARNING
Explosion hazard
In case of non
-
compliance with the maximum permissible temperature, there is
the risk of explosion.
•
The coupling
may only be restarted if the turbo coupling temperature is below
the maximum permissible temperature allowed when switching on the motor!
Maximum allowable
temperature
Operating manual
of turbo coupling

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BTS-Ex, non-contacting thermal switch unit
Technical Data
3 Technical Data
3.1 Switching element
Fig. 2
The following switching elements are available for the different turbo coupling sizes:
Dimension of thread M18x1.5 M24x1.5
Nominal response temperature 85 / 90 / 100 / 110 /
125 / 140 /160 / 180 °C 85 / 125 / 140 / 160 / 180 °C
suitable for coupling size 366 – 650 750 – 1150
Response tolerance ± 5 °C
Trip temperature approx. 40 K below the response temperature
Width across flats 27 32
Tightening torque 60 Nm 144 Nm
Classification is II 2GD
Ui = 10 V Ii = 50 mA Pi = 50 mW
Service temperature in the coil
area
-40 °C to +120 °C
Service temperature in the
area of the thermostatic switch
to 90 °C (T5), to 125 °C (T4), to 190 °C (T3)
Table 1
SAFETY INFORMATION
•
The type of switching element is stamped in on the housing indicating:
- Voith
- Nominal response temperature
- Ex marking II Ex i X
- Serial number (example: Voith 140 °C II Ex i X 1234 5678)
•
The nominal response temperature of the switching element is determined in
connection with the the coupling design.
~ 47
~ 22
~ 45.5
~ 22
M24x1.5
M18x1.5
Ø 41
M24x1.5
Ø 41
M18x1.5

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-Ex, non-contacting thermal switch unit
Technical Data
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3.2 Initiator, mounting flange
Fig. 3
Annex Type: NJ 10-22-N-E93-Y106925
NJ 10-22-N-E93-Y30627
NJ 10-22-N-E93-Y30629
NJ 10-22-N-E93-Y245590 (new design, cable length 2 m)
NJ 10-22-N-E93-Y246868 (new design, cable length 5 m)
NJ 10-22-N-E93-Y246869 (new design, cable length 10 m)
3.3 Evaluator
Annex Type: KFD2-SR2-Ex2.W.SM
31
Ø 22
29
~ 12
~ 6
46
60
Initiator shown with mounting flange
45
75

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BTS-Ex, non-contacting thermal switch unit
User Information
4 User Information
This manual will support you in using the non-contacting thermal switch unit (BTS-Ex)
in a safe, proper and economical way.
If you observe the information contained in this manual, you will
– increase the reliability and lifetime of the unit,
– avoid any risks
– reduce repairs and downtimes.
This manual must
– always be available at the BTS-Ex place of use,
– be read and used by every person who works on the unit or commissions the
same.
You will find further documents which have to be regarded at any rate, in the
annex.
The non-contacting thermal switch unit has been manufactured to the latest design
standard and approved safety regulations. Nevertheless, the user's or third party's life
may be endangered or the unit or other property impaired in case of improper
handling or unintended use.
Spare parts:
Spare parts must comply with the technical requirements stipulated by Voith. This is
ensured by using original spare parts.
Installation and/or use of non-original spare parts may negatively change the mecha-
nical properties of the BTS-Ex and may thus impair safety.
Voith is not liable for any damages resulting from the use of non-original spare parts.
Use only appropriate workshop equipment for maintenance. Professional
maintenance and/or repair can only be guaranteed by the manufacturer or an
authorized specialist workshop.

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-Ex, non-contacting thermal switch unit
User Information
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This manual has been issued with utmost care. However, should you need any further
information, please contact:
Voith Group
St. Pöltener Str. 43
89522 Heidenheim, GERMANY
Telefon: + 49 7951 32 1666
E-Mail: [e-mail]
Internet: www.voith.com/fluid-couplings
© Voith 2020.
Distribution as well as the reproduction of this document and the utilization and
communication of its contents are prohibited unless expressly permitted. Offenders
will be held liable for the payment of damages. All rights reserved in case a patent is
granted, or a utility model or design is registered.
Voith reserves the right for modifications.

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BTS-Ex, non-contacting thermal switch unit
Safety
5 Safety
5.1 Safety information
Safety information indicating the descriptions and symbols as described in the
following are used in the operating manual.
5.1.1 Structure of safety information
DANGER WORD
Results of a hazardous situation
Source of hazard
•
Warding off of danger
Danger word
The danger word divides the severity of the danger in several levels:
Danger word
Severity of danger
DANGER
Death or serious injury (irreversible personal
injury)
WARNING
Death or serious injury possible
CAUTION
Minor or moderate injury possible
NOTICE
Possibly damage to property of
- the product
- its environment
SAFETY INFORMATION
General applications details, useful
information, safe job procedure and proper
safety measures
Table 2
Results of a hazardous situation
Hazard consequences indicate the kind of hazard.
Source of hazard
The source of hazard indicates the cause of hazard.
Warding off of danger
Warding off of danger describes the measures to be taken to ward off a danger.

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-Ex, non-contacting thermal switch unit
Safety
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5.1.2 Definition of safety symbols
Symbol
Definition
Explosion hazard
Marking with the Ex-symbol indicates possible hazards which have to be
observed for the use in potentially explosive atmospheres.
Table 3
5.2 Intended use
– The non-contacting thermal switch unit (BTS-Ex) serves for the non-contacting
temperature monitoring of Voith turbo couplings and has been designed for
industrial applications. Any use beyond that described herein, e.g. for operating or
application conditions that have not been agreed upon, is deemed unintended.
– Intended use also includes observing this installation and operating manual.
– The manufacturer is not liable for any damages resulting from unintended use.
The risk has to be borne solely by the user.
5.3 Unintended use
– Design range is not met.
– Any use beyond that described herein, e.g. for higher powers, higher speeds, or
operating conditions that have not been agreed upon, is deemed unintended.
– Moreover, it is not permitted to use BTS-Ex non-contacting thermal switch units or
spare parts from third parties.
Design range

Operating manual
of turbo coupling

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BTS-Ex, non-contacting thermal switch unit
Safety
5.4 General information as to dangerous situations
For all work performed on the non-contacting thermal switch unit, please ob-
serve the local regulations for the prevention of accidents as well as the regula-
tions for installation of electrical equipment!
WARNING
Explosion hazard
In case of non
-compliance with the regulations or impermissible change, there
is
the risk of explosion.
•
When using the non-
contacting thermal switch unit in potentially explosive
atmospheres, observe the local regulations applicable to electrical equipment
in potentially explosive atmospheres! Changes on electrical equipment for
pot
entially explosive atmospheres, including connecting lines, are not
permitted.
Hazards while working on the non-contacting thermal switch unit:
DANGER
Electric shock
On account of incorrectly mounted or incorrectly connected electrical
components, and disconnected electric connections, persons could get an
electric shock and be severely injured, possibly with fatal consequences.
Incorrectly mounted or incorrectly connected electrical components and dis
con
-
nected ele
ctric connections may cause damages to the machinery.
•
A qualified electrician has to properly carry out the connection to the electric
supply network considering the system voltage and the maximum power con-
sumption!
•
The system voltage has to be in confor
mity with the system voltage indicated
on the nameplate!
•
There has to be a corresponding electrical protection by a fuse on the
network side.

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-Ex, non-contacting thermal switch unit
Safety
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Electric shock:
DANGER
Electrostatic processes
Electrostatic charging may injure persons by an
electric shock.
•
Allow only a qualified electrician to install the equipment into which the turbo
coupling is installed.
•
The unit and the electrical installation are provided with ground connections.
Working on the turbo coupling:
WARNING
Risk of
injury
While working on the turbo coupling, there is the risk of injury through cutting,
crushing, burns and cold burns in case of minus degrees.
•
Please observe the installation and operating manual of the turbo coupling!
•
Never touch the turbo coupling without wearing protective gloves.
•
Start to work on the turbo coupling only after it has cooled down.
•
Ensure that there is sufficient light, a sufficiently large working space and
good ventilation when working on the turbo coupling.
•
Switch off the unit in
which the turbo coupling is installed and secure the
switch against inadvertent switch-on.
•
For all work performed on the turbo coupling ensure that both the drive motor
and the driven machine have stopped running and that unintended starting is
absolutely impossible!
Noise:
WARNING
Hearing loss, permanent impairment of hearing
The turbo coupling generates noise during operation. If
the A-
classified
equivalent sound pressure level L
PA, 1m
exceeds 80 dB(A), this may cause
impairment of hearing!
•
Wear ear protection.
Sound pressure
level

cover sheet of
operating manual of
turbo coupling