Voith BTS User manual

Installation and Operating Manual
(Translation of the original installation and operating manual)
BTS
Non-contacting Thermal Switch Unit
Version 10, 2017-12-15
3626-011500 en, Protection Class 0: public

Installation and Operating Manual / Version 10 / 3626-011500 en / Protection Class
0: public / 2017-12-15
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BTS, non
-contacting thermal switch unit
Contact
Contact
Voith Turbo GmbH & Co. KG
Division Industry
Voithstr. 1
74564 Crailsheim, GERMANY
Tel. + 49 7951 32 599
Fax + 49 7951 32 554
vtcr
[e-mail]
www.voith.com/fluid
-couplings
3626
-011500 en
This document describes the state of de-
sign of the product at the time of the
editorial deadline on 2017
-12-15.
Copyright © by
Voith Turbo GmbH & Co. KG
This document is protected by copyright.
It must not be translated, duplicated
(mec
hanically or electron
ically) in whole
or in part, nor passed on to third parties
without the publisher's written approval.

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BTS, non-contacting thermal switch unit
Contents
Contents
1Possible Applications, BTS Characteristics 5
2BTS Functioning 6
2.1 Switching element 7
2.2 Initiator 7
2.3 Evaluator 7
2.4 Isolating switch amplifier 7
2.5 Interaction of BTS components 8
3Technical Data 9
3.1 Switching element 9
3.2 Initiator, mounting flange 10
3.3 Evaluator and isolating switch amplifier 10
3.3.1 Evaluator 10
3.3.2 Isolating switch amplifier 230 V AC 10
3.3.3 Isolating switch amplifier 20…30 V DC 10
4User Information 11
5Safety 13
5.1 Safety information 13
5.1.1 Structure of safety information 13
5.1.2 Definition of safety symbols 14
5.2 Intended use 14
5.3 Unintended use 14
5.4 General information as to dangerous situations 14
5.5 Remaining risks 18
5.6 What to do in case of accidents 18
5.7 Information with regard to operation 18
5.8 Qualification of staff 19
5.9 Product monitoring 19

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BTS, non
-contacting thermal switch unit
Contents
6Installation 20
6.1 As delivered condition 20
6.2 Scope of supply 20
6.3 Mounting - switching element and initiator 21
6.4 Mounting, connection - evaluator, isolating switch amplifier 26
7Display and Setting of Evaluator 29
7.1 Display - evaluator 29
7.2 Setting - evaluator 30
8Commissioning 31
9Maintenance, Servicing 32
9.1 Outside cleaning 34
10 Disposal 35
11 Malfunctions - Remedial Actions, Troubleshooting 36
12 Queries, Orders Placed for Field Service Representatives
and Spare Parts 39
13 Spare Parts Information 40
13.1 Switching elements 40
13.2 Initiator, mounting flange 41
13.3 Evaluator 41
13.4 Isolating switch amplifier 41
14 Index 42
15 Annex 44
15.1 Initiator NJ10-22-N-E93-Y106925 44
15.2 Initiator NJ10-22-N-E93-Y30627 45
15.3 Initiator NJ10-22-N-E93-Y30629 46
15.4 Evaluator KFU8-DW-1.D-Y209869 47
15.5 Isolating switch amplifier KFD2-SOT2-Ex2 48
15.6 Isolating switch amplifier KFA6-SOT2-Ex2 49
15.7 List of VOITH representatives 50

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BTS, non-contacting thermal switch unit
Possible Applications, BTS Characteristics
1 Possible Applications, BTS
Characteristics
The non-contacting thermal switch unit (BTS) is a monitoring system for Voith turbo
couplings.
– The BTS 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 resets automatically.
– The BTS can be used for Voith turbo couplings from size 206.
WARNING
Explosion hazard
If no isolating switch amplifier is used, there is the hazard of explosion.
•
As the control circuit of the evaluator is not
intrinsically safe, provide an
appropriate isolating switch amplifier between evaluator and initiator!
•
The BTS must not be used as safety device to limit the maximum permissible
surface temperature of the turbo coupling in potentially explosive atmos
-
pheres!

BTS, non
-contacting thermal switch unit
BTS Functioning
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2 BTS Functioning
The non-contacting thermal switch unit (BTS) consists of three components:
– Switching element
– Initiator with mounting flange
– Evaluator
Optionally, if an intrinsically safe control circuit is required:
– Isolating switch amplifier, two-channel for up to 2 initiators
Fig. 1
a = 4 ± 1 mm
a
Evaluator
Isolating switch
amplifier
Turbo coupling
Initiator
Mounting flange
Switching element

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BTS, non-contacting thermal switch unit
BTS Functioning
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 is again ready for service (it resets
automatically).
2.2 Initiator
The initiator has been designed as 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.
The evaluation starts either by switching on the supply voltage or by an external
trigger signal.
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.
2.4 Isolating switch amplifier
The isolating switch amplifier transmits digital signals from the potentially explosive
area.
Sensors or mechanical contacts may work as transducing sensor.
The intrinsically safe inputs are safely isolated from the output and power system.
Nominal response
temperature
Chapter 3.1

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-contacting thermal switch unit
BTS Functioning
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2.5 Interaction of BTS 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.
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 ensure that both the
drive motor and the driven machine have stopped running and that a re-
start
is absolutely impossible!
•
The coupling may only be restarted if the turbo coupling temperature is below
the maximum permissible temperature allowed when switching on the motor!
Installation, position
Chapter 2
Cutoff frequency
Chapter 3.3.1
Maximum
permissible
temperature
Operating manual
of turbo coupling

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BTS, 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 M12x1.5 M18x1.5 M24x1.5
Nominal response temperature 125 °C 85 / 90 / 100 / 110 /125 / 140 /
160 / 180 °C
85 / 125 / 140 /
160 / 180 °C
Suitable for
coupling sizes ... 206 – 274 366 – 650 750 – 1330
Response tolerance ± 5 °C
Trip temperature approx. 40 K below the response temperature
Width across flats 17 27 32
Tightening torque 22 Nm 60 Nm 144 Nm
Table 1
SAFETY INFORMATION
•
The type of switching element is stamped in on the housing indicating:
- Dimension of thread
- Maximum peripheral speed
- and nominal response temperature
•
The nominal response temperature of the switching element is determined in
connection with the the coupling design.
~ 47
~ 22
~ 45.5
~ 22
~ 38.5
~ 12.5
M24x1.5
M12x1.5
M18x1.5
Ø 41
Ø 41
M12x1.5
M18x1.5
M24x1.5
Ø 41

BTS, 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
3.3 Evaluator and isolating switch amplifier
3.3.1 Evaluator
Annex Type: KFU8-DW-1.D-Y209869
3.3.2 Isolating switch amplifier 230 V AC
Annex Type: KFA6-SOT2-Ex2
3.3.3 Isolating switch amplifier 20…30 V DC
Annex Type: KFD2-SOT2-Ex2
31
Ø 22 29
~ 12
~ 6
46
60
Initiator shown with mounting flange
45
75

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BTS, non-contacting thermal switch unit
User Information
4 User Information
This manual will support you in using the non-contacting thermal switch unit (BTS) 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 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 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.

BTS, 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 Turbo GmbH & Co. KG
Division Industry
Voithstr. 1
74564 Crailsheim, GERMANY
Tel. [phone]
Fax [phone]
[e-mail]
www.voith.com/fluid-couplings
© Voith Turbo 2017.
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 Turbo reserves the right for modifications.

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BTS, 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
Hazard consequences
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
Hazard consequences
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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-contacting thermal switch unit
Safety
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5.1.2 Definition of safety symbols
Symbol
Definition
Danger of explosion
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) serves for the non-contacting
temperature monitoring of Voith turbo couplings. 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 non-contacting thermal switch units from
third parties.
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 danger 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 atmosph
eres! Changes on electrical equipment for
potentially explosive atmospheres, including connecting lines, are not
permitted.
Design range

Operating manual
of
turbo coupling

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BTS, non-contacting thermal switch unit
Safety
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
disconnected electric connections may cause damages to the machine.
•
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 conformity with the system voltage indicated
on the nameplate!
•
There has to be a corresponding electrical protection by a fuse on the
network side!
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.
•
Machine and electric installation are provided with grounding connections.

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-contacting thermal switch unit
Safety
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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 golves.
•
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 a re-
start 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

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BTS, non-contacting thermal switch unit
Safety
Operating fluid which sprays off or leaks out:
WARNING
Risk of losing sight due to operating fluid spraying off, risk of burning
In case of thermal overload of the turbo coupling, the fusible plugs respond.
Operating fluid leaks out through thes
e fusible plugs.
This may happen only in case of unintended use.
•
Persons close to the turbo coupling must wear safety goggles.
•
Please make sure that the spraying-
off operating fluid cannot get in contact
with persons.
•
If the fusible plugs spray off, switch off the drive immediately.
•
Electrical devices located near the turbo coupling need to be splash-guarded.
WARNING
Fire hazard
After the fusible plugs responded, spraying off oil may ignite on hot surfaces
causing fire, as well as releasing toxic
gases and vapor.
•
Make sure that spraying off operating fluid cannot get into contact with hot
machine parts, heaters, sparks or open flames.
•
Immediately switch off the driving machine when the fusible plugs respond.
•
Please pay attention to the information contained in the safety data sheets.
CAUTION
Danger of slipping
Slipping hazard due to spraying off solder of fusible plugs and leaking out
operating fluid.
•
Please provide a catch pan of sufficient size.
•
Immediately remove any leaking out solder and operating fluid.
•
Please pay attention to the information contained in the safety data sheets.
Unintended use
Chapter 5.3

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-contacting thermal switch unit
Safety
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5.5 Remaining risks
WARNING
Risk of personal injuries and damage to property
Unintended use or incorrect operation may cause death, serious injuries or minor
injuries as well as damage to property and the environment.
•
Only persons who are sufficiently qualified, trained and authorized are
allowed to work on or with the turbo coupling and the non-contacting th
ermal
switch unit.
•
Please observe the warnings and safety information.
5.6 What to do in case of accidents
SAFETY INFORMATION
•In case of accidents, please observe the local regulations, the operating
manuals and the operator's safety measures.
5.7 Information with regard to operation
SAFETY INFORMATION
•If irregularities are found during operation, immediately switch off the drive
unit.
Monitoring devices:
NOTICE
Damage to
property
Damage to turbo coupling due to monitoring devices not ready for service.
•
Check whether existing monitoring devices are in a state ready for service.
•
Repair any defective monitoring device immediately.
•
Never bypass safety devices.

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BTS, non-contacting thermal switch unit
Safety
5.8 Qualification of staff
Only qualified and authorized professional staff are allowed to perform work, such as
transportation, storage, installation, electrical connection, commissioning, operation,
maintenance, servicing and repair.
Qualified professional staff in the sense of this installation and operating manual are
persons who are familiar with transportation, storage, installation, electrical
connection, commissioning, maintenance, service and repair, and who have the
necessary qualifications for their job. Qualification has to be ensured by performing
training and giving instructions.
This staff must be trained, instructed and authorized to:
– operate and service machines in a professional manner in accordance with the
technical safety standards.
– use lifting appliances, slings (ropes, chains, etc.) and lifting points in a
professional manner.
– properly dispose of media and their components, e.g. lubricating grease.
– service and use safety devices in a manner that ensures compliance with safety
standards.
– prevent accidents and provide first aid.
Staff to be trained may only perform work on the turbo coupling and the non-
contacting thermal switch unit under the supervision of a qualified and authorized
person.
The staff in charge of any work to be done on the non-contacting thermal switch unit
must
– be reliable,
– have the legal age,
– be trained, instructed and authorized with regard to the intended work,
– observe EN 1127-1 Annex A and EN 1127-1 Section 7 if the unit is installed in
potentially explosive atmospheres. Use only tools which are approved for use in
potentially explosive atmospheres. Avoid formation of sparks.
5.9 Product monitoring
We are under legal obligation to keep the performance of our products under
observation, even after shipment.
Therefore, please inform us about anything that might be of interest to us. For
example:
– Change in operating data,
– experience gained with the machine,
– recurring problems,
– problems experienced with this installation and operating manual.
Our address:

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-contacting thermal switch unit
Installation
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6 Installation
WARNING
Risk of injury
Please observe, in particular,
Chapter 5 (Safety) when working on the non
-
contacting thermal switch unit!
•
Before beginning with the installation, ensure that an isolation of all
components is guaranteed.
•
The fusible plugs protect
the turbo coupling against damage due to thermal
overload.
Even when the BTS is used, it is not allowed to replace the fusible plugs by
blind screws or by fusible plugs with different nominal response temperatu
-
res!
•
Never operate the turbo coupling without fusible plugs!
6.1 As delivered condition
– Normally, the switching element with sealing ring,
– the initiator with mounting flange and
– the evaluator
are supplied as loose parts together with the turbo coupling.
6.2 Scope of supply
Please contact Voith Turbo in case of a subsequent installation of the BTS for
turbo coupling sizes 206 and 274!
Standard combinations of switching elements and fusible plugs:
Nominal response temperatures
Switching element
Fusible plugs
Color coding
160 °C
180 °C
blue
140 °C
160 °C
green
125 °C
160 °C
green
110 °C
140 °C
red
Table 4