WESTCAR ROTOMEC Series User manual

Original Instructions
WESTCAR s.r.l.
Via Monte Rosa 14
20149 - MILANO
Tel. [phone]
Fax [phone]
[e-mail]
www.westcar.it
Constant-fill
HYDRO
MECHANIC
COUPLINGS
ROTOMECROTOMEC
®
ROTOMEC ALFA
ROTOMEC BETA
M2021-ENG - ed. 2021-04

2
Po w e r T r a n s m i s s i o n
Installation and maintenance manual ROTOMEC
Denition: Constant - ll FLUID COUPLING
Type: _______________________________________ Code: _______________________________________
Series No _____________________________________ Year: ________________________________________
Transmission Fluid: _________________________ Filling: Standard Calibration
Actuation on primary wheel: internal ___________________
Temperature during start-up: max ____________ °C Rated operating temperature: ___________________ °C
Expected start-up time: _______________________ S Maximum start-up time: ________________________ S
Lubrication: standard constant self-lubricating
SAFETY/TEMPERATURE CONTROL DEVICES SUPPLIED:
TF (Fusible Plug) 96°C 120°C 145°C 180°C ____°C
ETP (Expandable Thermal Plug) 96°C 120°C 145°C 180°C ____°C
T09
(Plug with Thermostat and RPM counter) 100°C 120°C 145°C 160°C ____°C
STANDARD MANUFACTURE ATEX MANUFACTURE
Ambient: _____________ Max Temp.: __________°C Ambient: ZONE ______________ Max Temp: _______°C
DRIVE SIDE DATAS:
Installation: Horizontal Vertical
Type of engine: Diesel Petrol ________________________ Rpm
Electric Voltage: _____ V _____ Hz _____ Rpm
Installed Power: __________________ kW Power input: __________________________ kW
DRIVEN SIDE DATAS:
Installation: Flexible coupling:
YES NO
Drive - through pulley
ROTOFLEXI type ______ bore Ø _____ Primitive diameter: ___________________________
ROTOPIN type ______ bore Ø _____ Grooves section: ________ N° grooves: ___________
ROTOGEAR type ______ bore Ø _____ bore Ø ______________ bore Ø ________________
LAMELLAR type ______ bore Ø _____ ___________________________________________
OPTIONS:
Brake Disc type __________________ Brake drum type ___________________
CUSTOMER
TYPE OF MACHINE: __________________________ TYPE OF WORK: _______________________________
No-load start-up Full-load start-up Start-up n./hour _________ Consecutive start-up n. ____
Load inertia (PD2) ________________________ kgm2N° overloads ___________ Load start-up _______ sec.
Full-load start-up _________________________ sec. Bore drive end shaft _________________________ mm
Bore of driven end shaft ____________________ mm Operating area temperature ____________________ °C
ROTOMEC COUPLINGS
ORDER N.
ROTOMEC ALFA ROTOMEC BETA
WESTCAR s.r.l.
Via Monte Rosa 14
20149 - MILANO
Tel. [phone]
Fax [phone]
[e-mail]
www.westcar.it
0.1 TECHNICAL SHEET HYDROMECHANIC COUPLING
ALFA K0
ALFA K1
ALFA K2
BETA H
BETA J
BETA X
BETA Z
Part 0 – technical Sheet

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Po w e r T r a n s m i s s i o n
Installation and maintenance manual ROTOMEC
INDEX
PART 0 REFERENCE DOCUMENTS 2 - 7
0.0 DECLARATION OF INCORPORATION (ENCLOSED)
0.1 ROTOMEC COUPLING TECHNICAL DATA SHEET 2
0.2 INDEX 3
0.3 COMPONENT DEFINITIONS 4
0.4 MANUAL LAYOUT AND SYMBOLS 5 - 7
PART 1 INTRODUCTION INFORMATION 8 - 16
1.1 WESTCAR INSTRUCTION LETTER ON DELIVERY 8
1.2 HYDROMECHANIC COUPLING IDENTIFICATION 9
1.3 MARKING OF HYDROMECHANIC COUPLING ACCORDING TO ATEX STANDARD 10
1.4 WARRANTY 11
1.5 GENERAL INFORMATION ON DELIVERY 12
1.6 HYDROMECHANIC COUPLING DESCRIPTION 12
1.7 OPERATING PRINCIPLE 13
1.8 INTENDED USE AND SAFETY DEVICES 13 - 14
1.9 IMPROPER AND FORBIDDEN USE OF STANDARD AND ATEX COUPLINGS
15
1.10 REQUIREMENTS FOR STANDARD and/or ATEX INSTALLATION 16
PART 2 WARNINGS AND PRESCRIPTIONS 17 - 23
2.1 GENERAL SAFETY RULES 17 - 20
2.2 SAFETY RULES FOR POTENTIALLY EXPLOSIVE ATMOSPHERES 21
2.3 SAFETY DEVICES AND WARNING LABELS 22
2.4 SAFETY INSPECTIONS 23
PART 3 TRANSPORT AND INSTALLATION 24 - 31
3.1 TRANSPORT OF COUPLING WITH PACKAGE 24
3.2 HANDLING OF COUPLING WITHOUT PACKAGE 25
3.3 COUPLING STORAGE AND CONSERVATION 26 - 27
3.4 COUPLING PRE-ASSEMBLY 28 - 29
3.5 ASSEMBLY OF PULLEY FOR BETA COUPLINGS 30 - 31
PART 4 INSTALLATION AND COMMISSIONING 32 - 47
4.1 PRESCRIPTIONS FOR ROTOMEC COUPLING INSTALLATION IN HAZARDOUS ATMOSPHERES 32 - 33
4.2 FITTING OF ROTOMEC COUPLING ON DRIVE SHAFT 34 - 41
4.3 ASSEMBLY AND ALIGNMENT OF ROTOFLEXI FLEXIBLE COUPLING 42 - 43
4.4 ASSEMBLY AND ALIGNMENT OF SERIES AB FLEXIBLE COUPLING 44
4.5 SCREW TIGHTENING TORQUES FOR COUPLINGS AND ACCESSORIES 45
4.6 ROTOMEC COUPLING COMMISSIONING - STANDARD and ATEX MANUFACTURE 46 - 47
PART 5
OPERATION, REPLACEMENT AND/OR RESETTING OF OVERHEATING PROTECTION DEVICES 48 - 51
5.1 FUSIBLE PLUG - TF 48
5.2 EXPANDABLE PLUG - TE 49
5.3 PLUG WITH THERMOSTAT AND rmp CONTROLLER - T09 con PM 50 - 51
PART 6 TRANSMISSION OIL FILLING AND CALIBRATION 52 - 68
6.1 TRANSMISSION OIL TECHNICAL CHARACTERISTICS 52 - 53
6.2 TABLES FOR COUPLING FILLING 54
6.3 FILLING AND CALIBRATION OF HORIZONTALLY MOUNTED COUPLINGS 55 - 59
6.4 FILLING AND CALIBRATION OF VERTICALLY MOUNTED COUPLINGS 60 - 63
6.5 TRANSMISSION OIL REPLACEMENT IN HORIZONTALLY MOUNTED COUPLINGS 64 - 65
6.6 TRANSMISSION OIL REPLACEMENT IN VERTICALLY MOUNTED COUPLINGS 66 - 67
6.7 TABLE FOR RESIDUAL OIL DEPLETION IN VERTICALLY MOUNTED COUPLINGS 68
PART 7 ORDINARY MAINTENANCE 69 - 76
7.1 OIL LEAKAGE CHECK 69
7.2 OIL LEVEL CHECK AND TOP-UP 70 - 71
7.3 EXTERNAL CLEANING OF THE COUPLING 72
7.4 INSPECTION OF OVERHEATING CONTROL DEVICES 73
7.5 SERVICE RECORD 74 - 75
7.6 COUPLING OUTER PROFILE AND MAIN ELEMENTS 76
PART 8 INCONVENIENCES AND REMEDIES 77 - 78
PART 9 EXTRAORDINARY MAINTENANCE 79 - 82
9.1 COUPLING DISASSEMBLY FROM MACHINE 79
9.2 OPENING OF THE COUPLING AND SPARE PARTS REPLACEMENT 80 - 81
9.3 SPARE PARTS 82
PART 10 DECOMMISSIONING AND DEMOLITION 83
10.1 COUPLING DECOMMISSIONING 81
10.2 FLUID COUPLING DISMANTLING AND DEMOLITION 81

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Po w e r T r a n s m i s s i o n
ROTOMEC USe and Maintenance handbook
0.3 COMPONENTS DEFINITIONS
Layout and graphic design: Briefnglab. The rights of translation, reproduction and total or partial adaptation are prohibited in all countries.
ROTOMEC ALFA ROTOMEC BETA
POS. DEFINITION
1TRANSMISSION FLUID
2OUTER SHELLS (external part)
3
HOLLOW SHAFT and INNER PRIMARY WHEEL (internal part)
4OIL PLUG POSITION (STANDARD)
5RADIAL PLUG POSITION (OPTIONAL)
6FLEXIBLE COUPLING
7PRIMARY WHEEL
8ROTATING GASKETS
POS. DEFINITION
9CENTRIFUGAL MASSES
10 ROLLERS CENTRIFUGAL COUPLING
11 RADIAL SHELL SEALING
12 HEAD SCREW
13 PULLEY SLEEVE
14 PULLEY
15 RADIAL BEARINGS
TYPES OF HYDROMECHANIC COUPLINGS
ROTOMEC ALFA (in-line) ROTOMEC BETA (belt driven)
3 5 2
4 1 11 7
3 5 2
4 1 11 7 9
146
138 10 8 1515
12
10
Part 0 – reference docUMentS
12 15
9 8
8 15

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Po w e r T r a n s m i s s i o n
ROTOMEC USe and Maintenance handbook
0.4 MANUAL LAYOUT AND SYMBOLS
Part 0 - reference docUMentS
This handbook has been subdivided into topics in order to classify information and operators’ activity.
This handbook is composed of several PARTS (chapters) and sections dealing with operational topics to
enable correct installation, use and maintenance of the ROTOMEC hydromechanic couplings.
Pages have the following layout and contents:
This document is the property of WESTCAR srl. All copyrights reserved.
This handbook is an integral part to this partly completed machine and it has to be considered as a SAFETY
DEVICE; it provides both the purchaser and the personnel (operators and qualied technicians) with the
necessary installation, use and maintenance instructions in order to keep the product safe and in good working
order for its whole life-cycle.
We recommend to read and to fully understand the content of this manual.
Topics are dealt with in chapters and sections, so that each stage is clearly illustrated in a numbered step-
by-step sequence. At the beginning of each section a bar shows the symbols associated with the personnel
qualied for the task.
Any operation-related residual risk is highlighted through suitable symbols in the text. In the handbook some
symbols are used to highlight and differentiate particular instructions or recommendations, which are of crucial
importance for safe operation and/or correct use and maintenance.
These measures allow WESTCAR to draw operators’ and qualied technicians’ attention to the CAUTIONS,
WARNINGS OR NOTES concerning them.
For any further clarication on the content of this handbook, do not hesitate to contact your WESTCAR
Customer Support Service.
tel. [phone] email: [email protected]
fax [phone] web site: www.westcar.it
GRAPHIC DESIGN AND
OPERATION SEQUENCES
PRECAUTIONS,
WARNINGS OR
NOTES
for safety and
operation
SYMBOLS
-
hazard
- prohibition
- obligation
PAGE
NUMBERS
HEADING OF
CHAPTER
OR PART
AUTHORIZED
PERSONNEL
HEADING OF
SECTION OR
TOPIC
24
P ow e r T ra n s m i s s i o n
3.1 TRANSPORT OF COUPLING WITH PACKAGE
The handling and transport operations are reserved to the handling
technicians equipped with suitable personal protective equipment
(protection gloves, safety shoes). DANGER OF CRUSHING, CRASHING
AND/OR INJECTION
3.1.1
Upon reception of the supply, check the weight reported on the label.
CAUTION
DANGER OF TILTING AND CRUSHING:
The load within the packaging could be unbalanced; therefore abide by
the procedures set out. Do not roll or damage the packaging. RISK OF
OVERTURNING.
3.1.2
Spread the forks of the fork-lift truck (with capacity suitable for the weight to be
trasported) as much as possible. Lift the coupling with its packaging slowly and
transport it (keeping it as much close to the soil as possible, about 30 cm) and
put it under a shelter in a dry place; then get the fork-lift out of the way.
3.1.3
Open the upper part and remove the packaging.
CAUTION
DANGER OF ENVIRONMENTAL POLLUTION:
Do not dump packaging material in the environment, but keep it for any future
re-use or shipping to the manufacturer or dispose of it properly as industrial waste.
3.1.4
Remove any stiffening rib, plastic lm for internal protection and brackets that x
the hydromechanic coupling to the pallet.
NOTE
Should the product be sent to the factory for repair works or maintenance,
the hydromechanic coupling will have to be shipped in a new package.
The shipping procedure shall be previously agreed upon with WESTCAR.
3.1.5
Take the Original Instruction Handbook and check that the product is not dam-
aged, no parts are missing and the content complies with the order.
NOTE
Non-compliance must be reported to Westcar and it’s distributor within
eight days from the receipt date.
3.1.6
To store the coupling, observe what set out in section 3.3. STORAGE OF THE
COUPLING.
The transport the of coupling with packaging has thus ended; now it is
possible to follow the steps described in the next section.
Part 3 - tranSPort and inStallationROTOMEC USe and Maintenance handbook
25
P ow e r T ra n s m i s s i o n
To handle the hydromechanic coupling without its package, it is necessary to follow
this procedure:
The handling and transport operations are reserved to handling technicians
equipped with suitable personal protective equipment (protection gloves,
safety shoes). DANGER OF CRUSHING.
3.2.1
Take the instructions and follow the description.
CAUTION
RISK OF CUSHING. In order to hoist and handle the hydromechanic
coupling, use the suitable lugs and devices recommended by the manufac-
turer, available on request; do not use any other reference than the equip-
ment and lifting points recommended by the manufacturer.
3.2.2 - For couplings with more than 30 kg of weight:
The hydromechanic coupling is located inside its packaging with its axis in verti-
cal position. Screw in the threaded pin equipped with hoisting ring in the extrac-
tion hole of the coupling.
3.2.3
Sling the coupling through the hoisting ring with hoist lines of suitable load
capacity for the coupling weight (see Identication Plate).
3.2.4
By slow movements, lift the coupling and transfer it to a dry, sheltered place and lay it
on a wooden plane next to motor and drive end, where the coupling will be installed.
The transport of the coupling without packaging has thus ended; now it is
possible to follow the procedure as set out in the next section.
3.2 HANDLING OF THE COUPLING WITHOUT PACKAGE
3.2.2
3.2.3
3.2.4
3.2.1
Part 2 - WarningS and PreScriPtionS ROTOMEC USe and Maintenance handbook
Original Instructions
WESTCAR s.r.l.
ViaMonte Rosa 14
20149- MILANO
Tel.[phone]
Fax[phone]
[email protected]
www.westcar.it
Constant-fill
HYDRO
MECHANIC
COUPLINGS
ROTOMEC
ROTOMEC
®
ROTOMECALFA
ROTOMECBETA
M2021-ENG- ed. 2021-02

6
Po w e r T r a n s m i s s i o n
ROTOMEC USe and Maintenance handbook Part 0 – reference docUMentS
This signal warns the workers that the described task may involve
exposure to residual risks with harmful effects on health and it may result
in very serious accidents, should them fail to comply with the procedures
and safety regulations herein described.
SYMBOL CAUTION
This signal warns the workers that the described task may damage the partly
completed machine and its components; failing to comply with the safety rules
may involve consequent risks for the operator and/or the environment.
It provides information on the task in progress, when it needs to be highlighted
due to its great technical signicance.
The hydromechanic coupling bearing this mark has been manufactured
according to the ATEX standards in compliance with the ATEX Directive 2014/34
EU.
In combination with the text, they point out the type of residual risk that the task
in progress may involve:
Danger of ignition and/or zones with explosive atmosphere
General hazard
Heated areas, danger of burns
Moving components
Danger of explosion
Fire danger
Dangerous voltage and risk of electric shock
Risk of slippery oor and falling
In combination with the text, they point out the type of prohibition that shall be
observed during the described activity:
Do not touch and keep away
Do not remove protections and guards, when machine is operating
Do not lubricate or interfere with moving parts.
SYMBOL WARNING
SYMBOL NOTE
SYMBOL PRODUCT MANUFACTURED ACCORDING TO THE ATEX STANDARD
SYMBOL SYMBOLS OF DANGER
SYMBOL SYMBOLS OF PROHIBITION

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Po w e r T r a n s m i s s i o n
ROTOMEC USe and Maintenance handbookPart 0 – reference docUMentS
In combination with the text, they point out the type of individual protection that
must be used to carry out the described intervention:
It is mandatory to wear protection gloves
It is mandatory to wear protection shoes
It is mandatory to wear protective clothing
It is mandatory to use protection helmets
It is mandatory to disconnect voltage before any task
SYMBOL SYMBOLS FOR MANDATORY SIGNS
SYMBOL HANDLING OPERATOR
It identies the kind of worker, who is qualied for the task in question.
The workers, who qualify for this task must have thorough knowledge and
understanding of the manufacturer’s handbook instructions as well as
specic competencies and knowledge of hoisting equipment and systems,
slinging and safe handling features.
It identies the kind of worker, who is qualied for the task in question.
This qualication is based on thorough knowledge and understanding of the
manufacturer’s instruction handbook as well as the required training. Special
engineering competencies are required to accomplish mechanical installation
and assembly. When this sign is matched with the explosion protection symbol,
the technician or operator must have a profound and specic knowledge of the
safety rules necessary to work in these environments.
It identies the kind of worker, who is qualies for the intervention in question.
This qualication is based on thorough knowledge and understanding of the
manufacturer’s instruction handbook as well as the completion of the required
training. Specic requirements and competencies are required to carry out
both mechanical repair and ordinary maintenance. When this sign is matched
with the explosion protection symbol, the technician or operator must have a
profound and specic knowledge of the safety rules necessary to work in these
environments.
It identies the tasks solely and exclusively reserved to technicians of the
WESTCAR Customer Support Service.
SYMBOL MACHINE OPERATOR
SYMBOL MECHANICAL INSTALLER
SYMBOL EXTRAORDINARY INTERVENTIONS

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Po w e r T r a n s m i s s i o n
1.1 WESTCAR INSTRUCTION LETTER ON DELIVERY
If equipped with suitable ATEX marking, the hydromechanic coupling of the
ROTOMEC series has been designed and manufactured in compliance with the
2006/42/EC Directive (concerned points) and the ATEX 2014/34/EC Directive.
It is not harmful for the operator, if it is used according to the instructions of this
handbook and provided that the safety equipment is constantly kept in good
working order.
This paper aims at certifying that, on receipt of the hydromechanic coupling:
- the coupling safety equipment is undamaged and efcient;
- the hydromechanic coupling is delivered with this handbook and the user takes
the responsibility to read and understand it as well as to follow it step-by-step.
The manual must be kept in good condition and the instructions about
maintenance, safety inspections, warnings and prescriptions shall always be
kept available on site for the technicians, who are in charge of the installation
and nal operators.
The manufacturer is not liable for any modication, tampering or any alteration
accomplished in violation of what above described and dealt with in this
handbook. Any modication not duly authorised in written by Westcar may be
dangerous to safety, people’s and animals’ health or property near the machine.
The manufacturing company has committed itself to developing an easily
searchable guide aimed at illustrating any function and performance of the uid
coupling as well as the safety-related aspects to fully exploit its potential.
The drawings and any other document delivered with the hydrodynamic
coupling are the property of WESTCAR, which reserves all rights and forbids
any conveyance to third parties without its written authorization.
ANY INTEGRAL OR PARTIAL REPRODUCTION THROUGH ANY MEANS
OF THIS MANUAL AND ITS CONTENT, TEXT OR PICTURES, IS STRICTLY
FORBIDDEN.
Part 1 - introdUctory inforMationROTOMEC USe and Maintenance handbook

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Po w e r T r a n s m i s s i o n
ROTOMEC USe and Maintenance handbook
1.2 HYDROMECHANIC COUPLING IDENTIFICATION
Each WESTCAR hydromechanic coupling is equipped with a small
identication plate which, besides the manufacturing code and serial
number, shows important safety information necessary for transport
and handling, installation and maintenance as well as for its correct
use.
CAUTION
Any removal and/or alteration of the ID plate and the data
reported in it may determine the expiry of the warranty and the
loss of compliance with the mentioned directives.
To contact the manufacturer or other Customer Support Service
authorized by WESTCAR, always point out the data showed on
the identication plate.
Below you can read the content of the elds of the ID plates xed on
the ROTOMEC hydromechanical coupling.
POS. DESCRIPTION POS. DESCRIPTION
AWESTCAR logo JProduct serial number
BManufacturer’s identication data KOil ll data / Calibration
CName of the partly completed machine LWeight of the no-load hydromechanic coupling
DCoupling identication code abbreviation: type MMaximum admitted rotation speed
EComponent or accessory identication code NConnection to the drive end
FEC Marking OProduct code
GATEX marking and protocol no. (if any) PInstallation: horizontal / vertical
HATEX product protection class (if any) QDrive end: power/rpm
IProduction year
Part 1 - introdUctory inforMation
A B C I G L Q N O
D E J F H P K
M

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Po w e r T r a n s m i s s i o n
InStallation and Maintenance ManUal ROTOMEC
1.3 MARKING OF ATEX HYDROMECHANIC COUPLINGS
The ROTOMEC constant-ll hydromechanic coupling is manufactured to full
customer’s needs according to an explosion protection process, in compliance
with the 94/9/EC/ATEX directive.
The couplings are built
- Category I M2 for mining industry
- Category II 2 G/D for surfaces industry
The ATEX marking placed on the hydromechanic coupling denes its design and
production characteristics and its anti-explosion protection level as well as the limits
of its use.
M2 High protection category for mining industry
2High protection category for surface industries
IMining
II Surface
GGas
DDust
Assembly for gas ignition: IIB=Ethylene
IIC=Hydrogen acetylene
EPL Protection Level:
- Mb = Mining
Protection valid for ordinary functioning
and foreseeable malfunction
- Gb Db = Surface
Protection valid for ordinary function
and foreseeable malfunction
Class of temperature: T3=200°C
T4=135°C
Construction Safety Protection Mode
I/II M2/2 G/D Ex c Mb/Gb/Db IIB/IIC T3/T4
Ex - International Sign Ex
Symbol for ATEX marking (2014/34/UE directive)
European Compliance
Part 1 - introdUctory inforMation

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Po w e r T r a n s m i s s i o n
1.4 WARRANTY
The ROTOMEC couplings are submitted to the following controls:
- dimensioning test of single parts,
- concentricity and perpendicularity control of all assembled parts with respect to the rotation axis,
- balancingin G6.3 ISO grade of single components,
- inspection of seals on the whole surface and gaskets with 4 bar internal pressure.
Should abnormalities occur, please call your WESTCAR CUSTOMER SUPPORT SERVICE, which will help you as
early as possible.
Please always point out what follows:
A - Full client’s address,
B - Hydromechanic coupling type and serial number, as shown on the identication plate
C - Description of the defector abnormality found.
THE ROTOMEC CONSTANT-FILL COUPLING IS COVERED BY THE FOLLOWING WARRANTY:
1 Warranty Conditions
The WESTCAR guarantee term is 12 months (barring different forms of contract) for all defective mechanical parts with
exemption of all worn parts. The guarantee term starts from the machine delivery date as shown in the delivery note.
2 Defect Report
The purchaser shall notify in written to WESTCAR within 8 days the defect found.
3 Defective Materials
WESTCAR may solve any problem due to material, machining or design defects, under the terms set out in point
1 of the warranty.
4 Warranty Extension
In case of repair or replacement of hydromechanic coupling parts, this warranty will not be extended. Our
six-month warranty only covers the parts replaced in our workshops.
Our technician’s travelling and maintenance expenses as well as the shipping expenses borne for the removal of
any defect will be fully charged.
5 Reserved Evaluation
The defective parts shall be returned to WESTCAR, which reserves the right to check them in its own workshops
in order to identify the real defects or the external reasons which may have caused the damage. If no defect can
be found in the product parts, WESTCAR reserves the right to debit the full cost of the parts previously replaced
and covered by this warranty.
TO BE COVERED BY THE BUYER:
1 Transport of Materials
Costs and risks of transport of the defective, repaired parts as well as of the parts supplied for replacement, inclusive
of any custom duties, are to be borne by the purchaser.
2 Obligations from Warranty
Repair or replacement of the defective parts amount to full satisfaction of the obligations stemming from this warranty.
3 Direct and Consequential Damages
This warranty shall NOT include any consequential damage and specically any machine standstill or production
downtime.
4 Wear-and-Tear of Materials
The warranty does not cover the usual wear-and-tear of any material.
5 Exclusion from Warranty
Any damage resulting from improper or negligent use, wrong maintenance of the part, transport or any circum-
stance other than operating or manufacture defects is not included in this warranty.
6 Disclaimer of responsibility
Warranty cover expires in case of improper use, wrong application and disregard of the instructions of this hand-
book.
All WESTCAR products are covered worldwide by this “Product Liability Insurance”
Part 1 - introdUctory inforMation ROTOMEC USe and Maintenance handbook

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Po w e r T r a n s m i s s i o n
1.5 GENERAL NOTES ON DELIVERY
Upon delivery, please check that the number of packages matches what reported
in the delivery note:
- ROTOMEC hydromechanical coupling
- Use and maintenance handbook (Original Instructions)
- Warning plate kit
- Over heating control devices (TF,TE,PM+T09)
- Accessories (if any)
Please also check what follows:
1- the parcel is intact,
2- shipping data (consignee’s address, number of parcels, order no.) matches
the order and the goods delivery note.
3- the delivered objects are not damaged.
Should any of the parts be damaged or missing, please inform immediately
(within 8 days from receipt) the manufacturer or the local distributors or
agents, the forwarding agent and/or the insurance company providing details
(photographs, if needed).
The operator in charge of the maintenance must conveniently store the
supplied materials under shelter, in a dry and safe place, not accessible
to unauthorized personnel.
1.6 HYDROMECHANICAL COUPLING DESCRIPTION
The ROTOMEC constant lling hydromechanical coupling consists of two
impellers opposite to each other, one connected to the motor shaft or motor
part, called pump, and the other connected to the machine or driven part, called
turbine.
The pump and the turbine are not connected to each other and the transmission
of motion and the torque in absence of usury, through a suitable transmission
uid, with which the hydromechanical coupling is lled.
The mechanical power supplied by the motor or motor part, to which the cou-
pling pump is connected, is transformed into hydrodynamical energy of the
transmission uid (inside the coupling) that, in contact with the opposite turbine,
it is again converted into mechanical energy, with the progressive transmission
of the torque to the driven part.
On the opposite side of the pump (between the pump and the cover) there is a
centrifugal coupling, consisting of four centrifugal masses with wear-resistant
rollers that grip radially on the external ring of the pump, allowing the residual
sliding to be neutralized, giving a power transmission and rotation efciency of
100%.
The operating principle of the transmission torque of the ROTOMEC coupling
provides for a series of important advantages for the mechanical protection of
transmission elements: soft starts, a remarkable reduction in power and energy
consumption on start-up as well as an important protection against overload at
full capacity.
Part 1 - introdUctory inforMationROTOMEC USe and Maintenance handbook

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Po w e r T r a n s m i s s i o n
1.7 WORKING PRINCIPLE
To operate, the mechanical status of the hydromechanic coupling and the transmission
uid it contains must undergo three main changes:
Step 1: DRIVE END STOP
The stopping of the motor or the drive end, which the pump is connected to, deter-
mines a state of hydrostatic equilibrium of the lling uid inside the
hydromechanic
coupling and the lack of motion and torque transmission.
Step 2: START-UP
By starting the motor or drive end, the pump starts speeding up the transmission
uid by progressively creating a hydrodynamic dragging force in the hydraulic cir-
cuit of the coupling, which imparts motion and transmits the torque to the turbine
(or driven end). This step results in a higher slip of the transmission uid and the
subsequent conversion of the force into thermal energy or heat. During the start-up
phase, the torque is transmitted by the characteristic ow pattern of the uid in the
hydraulic circuit of the coupling and by the type and level of transmission uid.
During the transmission phase, takes places the gradual connection of the internal
centrifugal coupling to hydromechanics coupling pump.
Step 3: OPERATION AT FULL CAPACITY
Once operation at full capacity is reached, the hydromechanic coupling transmits
100% of torque and speed to the driven machine. The full capacity operation of the
ROTOMEC coupling occurs in the absence of sliding of the input revolution com-
pared to the output ones, thanks to the combination of the hydromechanic circuit
state and the internal centrifugal coupling.
1.8 INTENDED USE AND SAFETY DEVICES
INTEDED USE
The ROTOMEC constant-ll hydromechanic couplings have been designed
and built to transmit the torque (or torsional moment) from the motor (or drive
end) to the driven machine through a suitable internal transmission uid, so to
obtain a gradual start-up without resorting to any starting equipment (delta-star
start-up, inverter, static starter) and full transmission of 100% of the torque and
the number of the revolution (without sliding).
The correct intended use of the constant-ll
hydromechanic coupling is determined
by an installation, which complies with the following requirements:
- correct dimensions of the coupling (size),
- quantity and type of transmission uid (transmission oil) for the type of
requested start-up,
- maximum number of consecutive start-up procedures / start-up procedures
per hour
- suitable safety and temperature control devices
- correct use of both the standard and ATEX version of the coupling designed
for hazardous areas.
- correct connection of the driving end to the external or internal side of the
uid coupling.
Each hydromechanic coupling is thus designed for a specic industrial
application, that shall be subsequently respected.
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Po w e r T r a n s m i s s i o n
CAUTION
It is not allowed to change colour or replace the pad of fusible material
in the safety and overheating control devices. DANGER OF OVERHEATING
OF THE COUPLING DUE TO THE TAMPERING
DRIVE END CONNECTION TO THE COUPLING
When assembling, the drive part (motor) must always be connected
WARNING
It is forbidden the installation of ROTOMEC hydromechanic coupling
with motor side connected to the external part.
COUPLING DIMENSIONING
The coupling dimensioning ( hydromechanic coupling size) and lling are dened
as a function of the power and rpm of the driving end and the torque required by
the driven machine (see identication plate).
START-UP TYPE
The conguration of the hydromechanic WESTCAR coupling is determined by
the quantity of transmission uid in the coupling, this pattern denes the ratio
between the STARTING TORQUE (ca) and the RATED TORQUE (cn), thus
showing a typical transmission curve on start-up.
MAXIMUM NUMBER OF START-UP PROCEDURES
In the event of difcult start-up of the coupling (on load or due to frequent
machine start-up), when temperature increases too much if compared to normal
operating conditions, it is necessary not to exceed the MAXIMUM NUMBER
OF START-UP PROCEDURES/HOUR AND/OR THE MAXIMUM NUMBER
OF CONSECUTIVE START-UP PROCEDURES, which shall comply with the
results obtained from the formulas reported in the WESTCAR catalogue.
SAFETY AND TEMPERATURE CONTROL DEVICES
The constant-ll hydromechanic coupling is congured according to the specic
customer’s needs and equipped with one or more safety and/or overheating
control devices (TF = Fusible plug, TE = Expandable Trip Plug or PM+T09 =
plug with thermocouple and rpm controller, SCD = device for overload control).
These devices become an integral part of the coupling conguration and further
dene the eld of application and the boundaries of its intended use (see chap-
ter PART 5). They perform an important safety function against overheating
phenomena, that may be originated by overloads on the driven end or abnormal
conditions.
IDENTIFICATION OF THE INTERVENTION TEMPERATURES OF THE DEVICES
The overheating control devices TF, TE and PM are identied through special
stamping and suitable colours, that make easier to recognize the special fea-
tures of each device:
TF TE PM
BLUE 96°C
WHITE 120°C
RED 145°C
GREEN 180°C
BLUE 96°C
WHITE 120°C
RED 145°C
GREEN 180°C
BLUE 100°C
WHITE 120°C
RED 140°C
GREEN 160°C
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Po w e r T r a n s m i s s i o n
1.9 IMPROPER AND FORBIDDEN USE OF STANDARD AND ATEX COUPLINGS
CAUTION
Any deviation from the use previously explained in these Original
Instructions has to be considered as misuse and it is not allowed by WESTCAR.
It is especially forbidden to use the ROTOMEC constant-ll hydromechanic cou-
pling for the following applications:
- as revolution limiter,
- when the drive end is mounted on the external side (indicated on the hydro-
mechanical coupling)
- when it is mounted in unsuitable locations or in locations, where temperature
is higher or lower than expected,
- when torque transmitted is higher than the value requested by the coupling,
- when rotation speed is higher than permitted (see plate),
- when the coupling is lled with a too large or too small amount of transmis-
sion uid in comparison with the quantity reported by the manufacturer,
- when transmission uids are not appropriate or do not match the uids rec-
ommended by the manufacturer,
- when the start-up time is higher than the maximum time expected,
- when start-up cycles occur in close sequence or exceed the number recom-
mended by the manufacturer,
- in default of safety and temperature control devices or if devices have been
tampered with, deteriorated or are different from what reported on coupling
conguration (see Technical Data Sheet),
- in case the motor is lacking of an automatic shutdown device, which may
block it in the event of transmission uid leakage (TF) or triggering of maxi-
mum temperature devices (TE or PM),
- when there are no suitable protections and/or uid containment elements for
couplings equipped with TF,
- if a suitable ventilation air intake is not available,
- when it is mounted next to intense heating radiation sources, hot air streams,
- next to strong vibration or percussion sources,
-
in case of tampering, removal, insertion, deformation due to shocks or re,
which may bring about unbalance,
- in case of both axial or orthogonal installation misalignments, which generate
unbalance or vibrations,
- when couplings without ATEX marking are used in potentially explosive
atmospheres,
- if checks and maintenance have not been planned as recommended by the
manufacturer.
ONLY FOR ATEX FLUID COUPLINGS
CAUTION
Do not install or use hydromechanic couplings without ATEX marking:
- when the coupling falls into an ATEX protection or temperature category,
which is not suitable for the hazardous location where it operates,
- in environments, where methane concentration is or may temporarily be
equal or higher than 1%,
- when the hydromechanic coupling is lacking of a suitable earthing system
and equipotential bonding.
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Po w e r T r a n s m i s s i o n
1.10 REQUIREMENTS FOR STANDARD e/o ATEX INSTALLATION
The hydromechanic coupling is a partly completed machine exclusively designed
for use in industrial environments and its installation must be in compliance with the
following requirements:
- indoor use in a protected location/room,
- ambient temperature between –20°C and +60°C (suitable types of oil must
be used),
- atmosphere of the operating zone void of corrosive or acid mists
- plant including a coupling equipped with a safety device TF (Fusible Plug) and
provided with both protection guards and uid collection containers, should the
uid leak due to overheating,
- mandatory use of appropriate biologic mineral oil to safeguard the environment
- installation room provided with interlocked protections, which prevent any
access when voltage is supplied,
- suitable room layout to prevent objects from falling or any access to the
coupling during operation,
- installation location far from intense vibration sources,
- installation location far from heat irradiation, hot air streams or electrostatically
charged air,
- easily accessible location for safe maintenance works,
- installation in potentially explosive atmospheres, where methane concentration
is lower than 1%.
- correct identication of
• enviorment: I mining / II surfaces ind.
• category: M2 mining / 2 surfaces ind.
• Epl Protection Level Mb mining: Gb/Db surface industries
• Gas Group Ignition: IIB /IIC
CAUTION
This handbook must be forwarded to the nal user of the machine
or partly completed machine, where the hydromechanic coupling will be
incorporated, because it provides information for its safe use and correct
maintenance schedule.
The installation of the ROTOMEC constant-ll hydromechanic coupling must be
compliant with the data reported on the identication plate, the manufacturer’s
instructions in the TECHNICAL DATA SHEET and in this Use, Maintenance and
Installation Handbook. For use in environment with characteristics different from
what pointed out above, please call the WESTCAR Technical Department.
CAUTION
Should oil leak after intervention of the fusible plug (TF), it is
mandatory to stop the motor as soon as possible; RISK OF OVERHEATING
of non lubricated bearings and gasket seals.
-
When using a coupling in over see machines, it is required to stop the motor
within 3 min.
- When using a coupling in machines without operator, it is required to install
an automatic shutdown device to immediately stop the engine.
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Po w e r T r a n s m i s s i o n
2.1 GENERAL SAFETY RULES
2.1.1
Before installation, the customer has to make sure that the safety requirements
for installation are observed (see section 1.10 REQUIREMENTS FOR STAND-
ARD AND ATEX INSTALLATION). The temperature in the installation location
must respect the operating characteristics of each hydromechanic coupling
(see TECHNICAL DATA SHEET OF THE FLUID COUPLING).
2.1.2
Handling (hoisting and unloading) of the hydromechanic coupling must be
effected with lifting equipment of suitable load capacity recommended by the
manufacturer.
Do not use any equipment and hoisting point not expressely raccomended
by the manufacturer; the hydromechanic coupling centre of gravity is
irregular: RISK OF OVERTURNING AND/OR LOAD LOSS.
2.1.3
The installation of the hydromechanic coupling must respect all instructions
reported in the identication plate and the TECHNICAL DATA SHEET OF THE
HYDROMECHANIC COUPLING. The installation of the coupling, which is
not in compliance with the data reported on the identication plate and the
TECHNICAL DATA SHEET, is prohibited.
2.1.4
The hydromechanic coupling must be connected and held tightly in place at the
drive end through an integral clamping system using appropriate devices as
foreseen by the manufacturer (central clamping screw, see section 2.3).
Any installation of the hydromechanic coupling not integral to the
plant or accomplished through devices, which are not included in
the manufacturer’s recommended parts list, is not allowed. RISK OF
UNBALANCE AND/OR DYNAMIC FAILURE.
2.1.5
The installation room must have suitable air intakes for heat dissipation.
Hydromechanic coupling installation with no or insufcient air ow is not
allowed. DANGER OF OVERHEATING.
2.1.6
The hydromechanic coupling should never be exposed to heat sources, which may
rise its temperature; installation in hot rooms needs a suitable forced ventilation
system for heat dissipation.
Do not install the hydromechanic coupling next to heat sources, if no forced
ventilation is available. DANGER OF OVERHEATING.
2.1.7
The installation room of the hydromechanic coupling must be equipped with inter-
locked protections and suitable safety switch in order to prevent access during
component rotation and/ or when voltage is applied to the drive end.
No admittance to the hydromechanic coupling is permitted during
component rotation and/or when voltage is applied to the drive end.
DANGER OF DEATH.
2.1.8
In plants where the noise level is higher than 80 dB, suitable soundabsorbing
devices are required.
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Po w e r T r a n s m i s s i o n
2.1.9
The hydromechanic coupling equipped with fusible plug TF must have suitable
protections for hot oil containment and collection in case of overheating.
Do not install the hydromechanic coupling equipped with fusible plug TF if
no suitable protection is available to contain and collect hot oil. DANGER
OF SCALDING AND/OR SLIPPERY FLOOR.
2.1.10
Under abnormal operating conditions or when the hydromechanic coupling is
equipped with fusible plug TF, hot oil leakage may occur.
The hydromechanic coupling cannot be installed near cables or electric
equipment, which are accessible or not protected against high tempera-
ture. DANGER OF SHORT CIRCUIT AND/OR FIRE.
2.1.11
The hydromechanic coupling is equipped with one or more safety and temperature
control devices, whose triggering causes the driving end to automatically stop.
The drive end and the hydromechanic coupling must be prevented from
operating after the release of the safety and temperature control devices,
which the coupling is equipped with. In particular, the FP triggering causes
the transmission and bearing lubrication oil to leak.
DANGER OF OVERHEATING, SEIZURE AND/OR FIRE.
2.1.12
The hydromechanic coupling is equipped with one or more safety devices for
overheating control. Do not tamper with, remove and/or disable the installed
safety device.
After triggering, it is necessary to restore and/or replace the device with
an original spare part having identical triggering characteristics and to
reset it before restarting the drive end.
DANGER OF OVERHEATING, SEIZURE AND/OR FIRE.
2.1.13
The installation of the hydromechanic coupling must be effected by observing
the axial levelling and planarity between the driving and the driven end (see
enclosed instructions PART 5). Incorrect installation or higher tolerance val-
ues axial levelling and/or planarity between the drive and the driven end
than pointed out by the manufacturer cannot be authorized.
RISK OF DYNAMIC UNBALANCE AND VIBRATIONS.
2.1.14
All the components of the hydromechanic coupling undergo balancing in order
to avoid dangerous vibrations. Do not apply any unbalanced mass to the
coupling and/or remove aps or external parts of it. DANGER OF VIBRA-
TIONS AND/ OR STRUCTURAL FAILURE.
2.1.15
The assembly and/or disassembly of the hydromechanic coupling must be
effected with the suitable tools recommended by the manufacturer.
Do not hit, bore and/or bang on the external shells and the seats of the
coupling; do not use ames for assembling or disassembling it.
DANGER OF DEFORMATION, IRREVERSABLE IMBALANCE AND/OR
STRUCTURAL FAILURE.
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Po w e r T r a n s m i s s i o n
2.1.16
Upon request the hydromechanic coupling may be manufactured with anodized
shells and for installation in environments with aggressive agents or they may
be painted (max 200µm) with a suitable high-temperature resistant paint. Do
not paint the coupling with paints, which are inadequate and/or ammable
and/or do not apply a thicker coat. DANGER OF FIRE AND/OR BAD HEAT
DISSIPATION.
2.1.17
The hydromechanic coupling must be lled with transmission uid suitable for
the relevant start-up characteristics and the environment, where it is mounted.
Do not use transmission uids and/or oils not recommended by the
manufacturer (see SECTION 6.1 TRANSMISSION OIL TECHNICAL
CHARACTERISTICS). DANGER OF DAMAGED SEALS AND/OR SEIZURE
OF THE BEARINGS.
2.1.18
The hydromechanic coupling must be lled up in compliance with the type of
start-up. Do not operate the hydromechanic coupling without transmission
uid or with an insufcient quantity of uid. DANGER OF OVERHEATING,
DAMAGED SEALS, SEIZURE OF THE BEARING AND/OR FIRE IGNITION.
Do not use the hydromechanic coupling with too much transmission uid.
DANGER OF OIL LEAKAGE DUE TO INTERNAL OVERPRESSURE AND/OR
STRUCTURAL FAILURE
.
2.1.19
The hydromechanic coupling has been designed for a maximum amount of
start-up/hour (see WESTCAR Technical Catalogue).
Never exceed the maximum amount of start-up procedures/hour and/ or
never start-up for a longer time than allowed by the manufacturer. DANGER
OF OVERHEATING.
2.1.20
The standard hydromechanic coupling is designed for continuous operation
(uninterrupted rotation) for periods not exceeding 4 or 5 subsequent full days.
For long-lasting uninterrupted running, use more lubricating transmission
oils and/or for higher performance, ask for the special coupling with self-
lubricating bearings.
2.1.21
When the hydromechanic coupling and the drive end are stopped, the driven
end is free to rotate; the hydromechanic coupling cannot block the driven end
nor can it guarantee its motion irreversibility. Suspended or sloping loads require
a brake installed on the driven end.
2.1.22
Before gaining access to the hydromechanic coupling and/or before carrying
out any cleaning, maintenance, regulation or uid make up work, perform the
following steps:
- stop the drive end and wait for the moving parts to stop,
- disconnect the supply voltage and apply a suitable safety padlock,
- wait for the surfaces of the hydromechanic coupling to cool down (max
40°C) before starting the activity,
- use suitable protection gloves, safety devices and protection garments.
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Po w e r T r a n s m i s s i o n
2.1.23
Before admittance to the room, where the hydromechanic coupling is installed,
check for oil leakage; as an alternative, fully remove and dry out the coupling.
DANGER OF SLIPPING.
2.1.24
Should the transmission oil and/or parts of the hydromechanic coupling (gas-
kets and seals) catch re, please follow these steps:
- cut out power supply upstream,
- use suitable powder re extinguishers (see long-range nozzle) loaded with
A, B or C powders or carbon dioxide re extinguishers.
2.1.25
To clean the hydromechanic coupling, use disposable cloths made of cellulose
dampened with neutral detergents.
Do not use inammable solvents, liquid agents or dry synthetic cloths,
which may become electrostatically charged.
FIRE DANGER.
2.1.26
Regulation and/or maintenance shall be carried out by trained and authorized
Technicians.
Do not tamper and/or alter the state-of-the-art technology of the uid coupling.
2.1.27
Worn parts or triggered protections must be replaced by original spare parts
only; each hydromechanic coupling component has been expressly designed
to perform both an operational and a safety task.
FAILING TO OBSERVE WHAT ABOVE MAY RESULT IN DANGERS FOR
THE OPERATORS, TECHNICIANS, PEOPLE OR THE MACHINE, WHERE
THE COUPLING IS MOUNTED, WHICH THE MANUFACTURER MAY NOT
BE HELD LIABLE FOR.
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