Engine Operation Instruction(Vulkan)

Flange - Coupling - RATO C5.05.12.13.02.
69
(Vulkan)
M32
Flange - Coupling - RATO
(Vulkan)
en / 23.09.2008 FD038287 1/41

DOKU1G322TR053E
Highly-flexible VULKAN - RATO – R Couplings
Customer: Caterpillar
Comm.-No.: 310801841
Dimension Group: G322TR
Series: 2200
Drawing No.: 1G3220R053
Partslist No.: 1G322TR053
VULKAN Kupplungs- und Getriebebau

B. Hackforth GmbH & Co. KG
Postfach 200462, 44634 Herne / Germany
Heerstrasse 66, 44653 Herne / Germany
Tel. +49-2325/922-0
Fax +49-2325/71110
E-Mail: info.vkg@vulkan24.com
http://www.vulkan24.com
HTU UTH
Contents of Documentation:
Technical Data RATO-R-322T
General Drawing
1G3220R053
Partlist 1G322TR053
Flexible Part, Drawing EG3220000R
Partlist EG322T000R
Delivery Condition AG3220R053
InstallationandOperating Instructions E&B RATO_R_with Bushes G2120_G3120, G3220 a.

G3820 BR2200e
Aliment Instructions for highli flexible

VULKAN-RATO-S/R Couplings S/R-A- 1/2 to 5/2
Criteria for the inspection of

VULKAN-RATO-S/R Couplings S/R-CRIT-1/1a to 9/1a
Surface Protection COATING LP for

VULKAN RATO- S/R Couplings S/R/DS/DG-COAT-1/1 to 7/1
Technical Data for RATO-R Coupling
Size G322TR Drawing-No.: 1G3220R053
Rubber qual. TR
T KN kNm 80,0
T K max.1 kNm 97,0
T K max.2 kNm 360,0
' T max kNm 116,5
T KW kNm 24,0
P KV50 - total kW 1,24
-1
n K max min 1100
'Ka mm 5,5
'Kr mm 12,0
F ax1,0 kN 0,9
C rdyn kN/mm 3,6
nominal warm
C T dyn-total kNm/rad 320,0 224,0
rel . Damping < 1,13 0,79
The guide lines in the RATO - catalogue

R-ETD-5 have to be considered
VULKAN
Technische Daten
Kupplungs- und Getriebebau Zeichnungs Nr.:
G322TR.xls 11.03.2008
VULKAN: PRODUCTION Partslist
Manuf.Product: 1G322TR053-C Date: 23.06.2008

RATO-R Page: 1
Drawing: 1G3220R053 Printed by: HEINZK
Item Quant Part Number Description Dimensions Material Remark DM
1 1 EG322T000R Flex. Part G322TR St/Gummi
3 1 4G33R0022M-C Connecting Ring FM 1386 X 905 X 94.1 S355J2G3
5 1 4G32K0033M-C Hub FM 540 X 188 X 278.1 42CrMo4+QT EN10083-1
10 1 2G32K2000M-C MEMBR.ASSEMBLY
16 64 7033620000 DISC 20 42CrMo4+QT EN10083-1
19 32 7000120100-C HEXAGON BOLT M 20 X100 10.9 931M
20 32 7001120040-C HEXAGON BOLT M 20 X 40 10.9 933M
28 32 7020120000 HEX NUT M 20 10 934
29 32 7020020000 Hex Nut M 20 8 DIN934
35 24 7033630000 DISC 30 42CRMO4+QT EN 10083-1
36 24 7019130000 HEX NUT M 30 10 DINEN24032
40 12 7033612000 Disc FM 20 X 12.1 X 4.5 42CrMo4+QT EN10083-1
46 6 3G32K80000 BUSH FM 24 X 13,5 X 47 42CrMo4+QT EN 10083-1 EN 10083-1
47 6 7000112080 HEXAGON BOLT M 12 X 80 10.9 931M
48 6 7020112000 Hex Nut M 12 10 934
51 32 7010420100-C SOCK HD SCREW M 20 X100 10.9 912
52 32 7033620000 DISC 20 42CrMo4+QT EN10083-1
55 2 7042621080 DOWEL PIN FM 21H8 X 80 St50 K PASSUNG H8

VULKAN: PRODUCTION Partslist
Manuf.Product: EG322T000R Date: 23.06.2008

Elast. Teil Page: 1
Drawing: EG3220000R Printed by: HEINZK
Item Quant Part Number Description Dimensions Material Remark DM
1 2 EG321TR000 FLEX.ELEMENT ST/GUMMI
3 30 7020120000 HEX NUT M 20 10 934
4 90 7033620000 DISC 20 42CrMo4+QT EN10083-1
5 2 7005320060-C HEX FITTEDBOLT M 20 X 60 10.9 609 JS6
6 2 7020120000 HEX NUT M 20 10 934
7 6 7033720000 DISC 20 42CrMo4+QT EN10083-1
8 32 3G32K3000M-C Bush FM 45 X 21.5 X 40.35 42CrMo4+QT EN10083-1

Installation and Operating Instruction
E&B G2120R – G3120R
G3220 and G3820 series 2200
VULKAN-RATO-R Couplings
(membrane assembly with bushes)

B. Hackforth GmbH & Co. KG
Postfach 200462, 44634 Herne / Germany
Heerstraße 66, 44653 Herne / Germany
Phone: ++49-2325/922-0
Fax: ++49-2325/71110
E-Mail: info.vkg@vulkan24.com
http://www.vulkan24.com
Title Installation and Operating Instruction Subject RATO-R Standard Execution

Responsi Authoring Checked and released Document: E&B_Rato-R mit
Buchsen G2120 G3120 G3220 u.
bility 07.09.05 07.09.05 Version: 001
TB 10 Wolfgang Sprung Jürgen Kestermann Page: 1/8
Contents
1 General Safety Regulations .....................................................................................3
1.1 Symbol for industrial safety ......................................................................................3
1.2 Attention remark.......................................................................................................3
1.3 Safety regulations ....................................................................................................3
2 General information about the VULKAN RATO-R coupling .....................................3
3 Procedure before the installation .............................................................................4
3.1 Delivery condition of the RATO - R coupling............................................................4
3.2 Design of the flexible part.........................................................................................5
3.3 Difference between single-row and double-row coupling.........................................6
4 Assembly of the RATO-R coupling ..........................................................................6
4.1 Sequence of operations: ..........................................................................................6
5 Commissioning.........................................................................................................8
6 Maintenance.............................................................................................................8
6.1 Operating performance considering the mechanical properties of the Elastomer

material ....................................................................................................................8
6.2 Operating performace considering the chemical properties of the Elastomer

material ....................................................................................................................9
7 Replacement of the flexible part...............................................................................9
7.1 Disassembly of the flexible part ...............................................................................9
7.2 Assembly of the flexible part ....................................................................................9
8 Service and spare parts .........................................................................................10

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1 General Safety Regulations
1.1 Symbol for industrial safety
This symbol is added to all passages in this documentation concerning industrial safety and
including a risk to people's life and limb. Please follow these instructions and handle with the utmost
caution in these situations. Hand over all industrial safety instructions to other users as well.
1.2 Attention remark
Attention!
This "Attention!" remark is added to passages in this documentation which should be specially noted
in order to stick to the guidelines, regulations, instructions and correct flow of work and to prevent
any damages or destruction of the coupling.
1.3 Safety regulations
A coupling shield has to be provided, according to the accident prevention regulations.

According to EN 292, part 1 „Safety of Machines“, a shield against mechanical movements of ma-
chine parts (protection against accidental contact) is permissible, if a „usage according to the re-
gulations“ is guaranteed during all working conditions. At the same time a good ventilation of the
coupling has to be ensured (use of perforated plates).
If the possibility of exceeding the permissible speed of the coupling, nkmax, cannot be excluded com-
pletely, e. g. in case of an incident or because of a failure of the over-speed-trip in the system, the
coupling shield has to be so designed that possible coupling fragments cannot escape to the
surrounding environment.
For coupling applications in fast ships (Dynamically Supported Craft), the safety regulations of publi-
cation A373 of IMO (International Maritime Organisation) are valid. Dependant on the construction,
these machine arrangements contain components with a high rotating energy. When the coupling
runs outside of a casing, an external protecting device has to be provided to keep off possible
coupling fragments in any case.
2 General information about the VULKAN RATO-R coupling
The highly-flexible VULKAN-RATO-R couling is a rubber coupling, flexible in all directions. Its es-
sential parts are the flexible part, the membrane part and the connecting parts.
All connecting elements of the coupling are arranged without clearance. The RATO-R couplings
must be protected against permanent influence of oil and against the radiation of heat. Oil mist and
oil splashes are not detrimental.
The RATO-R elements are fit for use at ambient temperatures comprised between -50° (C) to +70°
(C). The ventilation holes guarantee good heat dissipation properties of the RATO-R coupling.
The free-of-play torque transmission in the RATO-R couplings and the large sectional rubber area of
the RATO-R elements guarantee good noise attenuation.

Responsi Checked and released E&B_Rato-R mit
Authoring Document: Buchsen G2120 G3120 G3220 u.
bility 07.09.05 07.09.05 Version: 001
Basically, the connection surfaces of the RATO-R couplings and the fitted as well as the finish bores
are protected by Tectyl. Before the installation of the coupling, these surfaces must be cleaned by
conventional solvents.
Pay attention to wear protective clothes (gloves, safety glasses etc.) while working
with solvents.
When the cleaned surfaces are completely dry, they must be slightly greased.
On behalf of the classification societies we herewith give the following instruction:
The torsional vibration behaviour of the drive system has to be checked and approved by the classi-
fication society. The expected and satisfactory behaviour is guaranteed only, provided that all com-
ponents comply to the values, the torsional vibration calculation is based upon. With respect to the
RATO-R coupling, this means to exactly keep to the dynamic stiffness and damping.
In case of a replacement of the RATO-R elements, only original VULKAN RATO-R elements with
coordinated technical data approved by the classification societies must be used!
To guarantee faultless function and optimum usage of the highly-flexible RATO-R couplings, certain
installation instructions have to be observed. Basically, each bolt connection participating in the
transmission of the torque must be tightenend with a torque spanner. The individual tightening torques
are given in the general drawing of the coupling No. 1G...
In case of flexible mounted systems, the alignment must be coordinated with the manufacturers of
engine, coupling and gearbox.
3 Procedure before the installation
3.1 Delivery condition of the RATO - R coupling

The RATO-R coupling is delivered according to drawing AG… in the partially assembled condition.
The fastening elements (items 16, 19, 28) and the bushes (item 11) have to be removed before the
assembly.
Item 4 is available in single-row or double-row execution (the sketch shows the double-row execution).
RATO-R G2120-G3120

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RATO-R G3220-G3820
3.2 Design of the flexible part

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During the assembly of two flexible elements into one flexible part it is important to pay attention to the
marking (notches). The position of the notches can be taken from the upper sketch or from the
element drawing EG…
3.3 Difference between single-row and double-row coupling

The only difference is the number of element-rows. All other assemblies are identical in construction.
During the assembly of these parts the work steps are identical.
4 Assembly of the RATO-R coupling
During transportation please pay attention to a sufficient carrying force of the lifting
devices. Only use approved transportation elements. Thoroughly fix the
transportation elements to the attaching device. Do not step under hanging loads.
Attention! While lifting the flexible element, take care not to damage the flexible element and
the add-on pieces.
Attention! Pay attention to the markings.
Attention! Tighten all screwed connections keeping the tightening torques given on the
drawings.
Please note:
The membrane assembly (item 10) cannot disperse into single parts. Inside the
membranes and the distance sheets are held by item 7, on the outside by items 5 + 6
(please refer to drawing No. 2G...).
4.1 Sequence of operations:

x The hub (5) has to be connected with the shaft end of the machine on the driven side using the
best available technology.
x Both machines are to be erected according to the installation dimension of the coupling.
x Push the membrane assembly (item 10) onto the hub (item 5) and connect it with the fastening
elements (items 22, 35, 36).
Attention! When pushing the membrane assembly (item 10) on the hub (item 5), please
pay attention that the heads of the screws (item 7) are located in the corre-
sponding bores provided in the hub’s flange (please refer to the following
picture).

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Bolts item 7
Bore in the hub’s flange
x Tighten the hexagon nuts (item 36) with a torque spanner. The corresponding tightening
torque can be taken from drawing No. 1G…
x Press the connecting ring (item 3) into the centering of the flywheel.
x Hang the flexible part (item 1) into a lifting device as a unit and arrange it in the system.
The flexible part (item 1) is available in single-row and double-row execution. The process
steps for the assembly remain the same.
x Establish the connection between flexible element (item 1), connecting ring (item 3) and the
engine on the driving side with the corresponding fastening elements.
x Insert two parallel pins (item 55) with two bushes (item 11) into the provided fitting bores
displaced by 180° (please refer to the following picture).
Bush item 11
Parallel pin item 55
Attention! The fitting bores are marked by notches at the element.

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x Insert the fastening elements (items 16, 19, 28) with one bush (item 11) each and tighten them
slightly.
x Tighten the fastening elements (items 16, 19, 28) with a torque spanner. The corresponding
tightening torque can be taken from the assembly drawing.
x Remove the parallel pins (item 55) and replace them by screwed connections.
x Tighten all screwed connections with the tightening torque given on the drawings.
Now the coupling is completely mounted and an alignment control has to be carried out. While doing
so, possible thermal expansions specific to the system have to be considered (please refer to the
enclosed alignment instructions No. S/R-A-1/3 up to 5/3).
5 Commissioning
Press „EMERGENCY SHUTDOWN“ in case of danger.

Do not touch any rotating parts.
Equip the coupling with a sufficient protection device against contact.
Attention! Make sure that the coupling is protected against contact with oil, solvents and
other chemicals.
A coupling shield has to be provided, according to the accident prevention regulations. If there are no
other objections having priority, these shields have to be made of perforated plates or expanded metal
to ensure a good ventilation of the coupling as well.
After completion of the assembly, the drive system is ready for operation, as far as the coupling is
concerned. We would like to point out that before commissioning you have to make sure that all
assembling auxiliaries have been removed from the RATO-R coupling.
6 Maintenance
Stop the system for maintenance work.

Safely protect the system against unintentional starting resp. rotation.
Function and service life of highly-flexible couplings are decisively determined by construction and
design, but also by the elastomer material selected and its resistance against environmental influ-
ences.
6.1 Operating performance considering the mechanical properties of the Elastomer

material
Basically, the highly-flexible RATO-R coupling does not require maintenance. In many cases, however,
the highly-flexible RATO-R coupling is an indicator for malfunctions in the system.
We recommend a check of the highly-flexible part in case of exceptional incidents, e. g. propeller
ground contact, short circuit, disturbance of synchronization, governor hunting or emergency cut-off.
Criteria for this purpose are given in document S/R-CRIT-1/1a up to 9/1a:
x Specification of limit values for the permissible permanent set depending on the size.
x Evaluation of surface cracks caused by ageing and their treatment including additional measures
according to document S/R/DS/DG-COAT-1/2 – 7/2.
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In addition to a check of the flexible part it is recommended to carry out an alignment control within the
scope of the engine inspection intervals.
Standard values are given in document S/R-A-1/3 up to 5/3.
6.2 Operating performace considering the chemical properties of the Elastomer

material
Caoutchouc (NR) is mainly used as elastic material in highly-flexible Elastomer couplings. Because of
its excellent dynamic properties (stablility / elasticity), actually there is no equivalent alternative ma-
terial available. Caoutchouc (NR) belongs to the DIEN caoutchoucs, however, it is subject to various
environmental influences, known under the collective noun „ageing“.
The immediate surrounding of the highly-flexible coupling in the system should be ventilated well in
order to prevent high ambient temperatures. To prevent early ageing, however, it should be ensured
that no „airflow“ will occur directly onto the rubber surface (especially waste air from generators).
An air swirl occurs closely above the coupling’s rubber surface which is desired because of its cooling
effect on the one hand, and on the other hand, however, continuously providing fresh air (O2). To pro-
tect the Elastomer material of the VULKAN couplings against these environmental influences, they are
equipped with the most progressive ageing protecting agents available for the rubber industry..
7 Replacement of the flexible part
7.1 Disassembly of the flexible part

Sequence of operations:
x Remove the connecting elements (items 16, 19, 28) with bushes (item 11).
x Put the flexible part (item 1) into a lifting device.
x Then remove the connecting elements between flexible element (item 1), connecting ring
(item 3) and engine flywheel.
x Remove and deposit the flexible part (item 1).
x Disasembly the connecting ring (item 3).
x Disassemble the bushes (item 46) at the old elements (item 1). For this purpose the fastening
elements (item 40, 47, 48) have to be removed.
x Clean all reusable parts.
So the disassembly of the flexible part is completed.
Please note:
When ordering spares for the flexible part (item 1), please give us the following information with
respect to the RATO-R coupling:
x 1. order No.
x 2. drawing No.
x 3. parts list No.
7.2 Assembly of the flexible part
Attention! Before the installation of the new flexible part, the six bushes (item 46) have to
be assembled.

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The sequence of operations for the assembly of the flexible part (item 1) has already been described
in paragraph 4.1.
After completion of the assembly, a new alignment control should be carried out at the drive system.
After completion of the assembly, the drive system is ready for operations, as far as the coupling is
concerned.
8 Service and spare parts
Contact address:
VULKAN Service dept.
Heerstraße 66
D-44653 HERNE
Phone: +49 (0)2325 922 179
FAX: +49 (0)2325 71110
Mobile: +49 (0)1782922179

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Ausrichthinweise für hochelastische Alignment Instructions for highly
VULKAN-RATO-S/R-Kupplungen flexible VULKAN RATO-S/R Couplings
Es wird vorausgesetzt, daß die Kupplung gemäß der It is assumed that the coupling metal parts have been
auftragsbezogenen mitgelieferten Einbau- und Be- installed without the flexible element assembly as
triebsanweisung ohne das elastische Teil in die Anlage stated in the VULKAN "Installation and Operating
eingebaut ist. Nur die Anschlußflächen sind von dem Instructions". The connection faces need to be cleaned
vor dem Versand zur Konservierung aufgebrachten to remove the Tectyl preserving agent.
Tectyl gereinigt.
Vor dem Einbau des elastischen Teils ist eine Aus- Prior to installing the flexible part, an alignment check
richtkontrolle durchzuführen. Hierbei ist die radiale, must be carried out. The radial, axial and angular
axiale und winklige Ausrichtung mit geeigneten Meß- alignment must be measured, using appropriate
geräten zu überprüfen. measuring instruments.
Wir empfehlen, bei der Ermittlung der einzelnen We recommend that both shafts are rotated by 90 deg
Meßwerte beide Wellen jeweils um 90 Grad weiter- before each measurement in order to eliminate any
zudrehen, da bei dieser Meßmethode Rundlauf- und inbuilt errors due to eccentricity and non-parallelism.
Planlauffehler nicht mitgemessen werden. Je genauer The accuracy of the alignment determines the reserves
die Anlage ausgerichtet wird, desto größer sind die the coupling will have to accomodate misalignments
Reserven der Kupplung für die Aufnahme von during operation.
Verlagerungen während des Betriebes.
RATO-Kupplungen sind in der Lage, große Verlage- RATO couplings are able to accommodate high
rungen der angeschlossenen Maschinen auszuglei- misalignments of connecting machines, without
chen, ohne größere Reaktionskräfte zu erzeugen und generating high reaction forces or reducing service life.
an Lebensdauer einzubüßen. Wir empfehlen im Nor- We recommend to work out an alignment- quality for
malfall eine praxisgerechte Ausrichtgüte anzustreben. the normal case oriented on practicability. Usually the
Unter praxisgerecht soll hier eine Ausrichtung ver- required alignments may be achieved with normal
standen werden, die ohne erhöhten Arbeits- und alignment measuring equipment without having to use
Meßgeräteaufwand erreicht werden kann. Die ent- sophisticated or time consuming procedures. The
sprechenden Ausrichtwerte sind der folgenden recommended alignment tolerances can be taken from
Tabelle zu entnehmen. the following table:
Bei Anlagen mit zu erwartenden großen Verlagerungen With respect to installations where high misalignments
empfehlen wir, die zulässigen Ausrichttoleranzen mit are expected we recommend to coordinate the
den Erstellern der Anlage abzustimmen. permissible alignment tolerances with the supplier of
the assembly.
Alle Werte gelten für den betriebswarmen Zustand1) / All data are valid for service-warm condition1)
Baugruppe empfohlene Ausrichttoleranz / recommended alignment tolerance [mm]
Dimension group radial axial2) winklig / angular3)
elastisch aufgestellt starr aufgestellt2)
elastic mounted rigid mounted
K 4010 - K 6020 0,5
+ 0,5 1,0 ± 0,25 ± 0,25 0,35
G 1210 - G 1340
G 1410 - G 2340 1,0
+ 1,0 2 ± 0,5 ± 0,5 0,35
G 2410 - G 3140 1,0
G 0310 - G 0520 + 1,0 2 ± 0,5 ± 0,6 0,5
G 3210 - G 3540
G 0810 - G 0820
1,0 ± 0,7 ± 0,8 0,6
+ 1,5 2,5
G 3610 - G 7340
1,0 ± 1,0 ± 0,8 0,6
+ 1,5 2,5
1.) Für Neuausrichtungen im kalten Zustand gelten 1.) Installation depending values are valid for service
anlagenspezifische Werte, die vom Ersteller der cold conditions. These values must be determined
Anlagen zu ermitteln und zu berücksichtigen sind. by the supplier of the assembly and have be to
2.) Siehe Montagekontrollmaß taken into account.
3.) Bezugsdurchmesser = Schwungradrezeß bzw. 2.) please refer to the assembly control dimension
Kupplungsaußendurchmesser 3.) relating diameter = flywheel recess respectively
outer Diameter of the coupling
S/R-A-1/3
Beispiel: Example:
Ohne Durchdrehsicherung Without torsional limit device
radial axial winklig/angular
Mit Durchdrehsicherung With torsional limit device
radial axial winklig/angular
Ziel jeder Ausrichtung muß sein, für den betriebs- The alignment should aim at the best possible ideal
warmen Zustand eine möglichst ideale Fluchtung zu alignment in the warm operating condition.
erreichen. Für die im kalten Zustand auszurichtenden For machines to be aligned in the cold condition a
Maschinen kann sich u.a. aus Gründen der Wärme- misalignment can occur due to thermal expansion
dehnung ein Fluchtversatz ergeben (siehe hierzu (please refer to note 1 in the table) which should be
Fußnote 1 in der Tabelle), dem die angegebenen superimposed by the tolerances given.
Toleranzen zu überlagern sind.
Einen Sonderfall stellen Anlagen mit elastisch gela- Installations with elastic mounted engines should be
gerten Motoren dar. Hier werden die Motoren gegen- given special consideration since these engines may
über dem Getriebe auch betriebswarm um einige settle relative to the gearbox in the warm condition due
Millimeter höher gestellt, um die zeitabhängige Setzung to the creep characteristics of the rubber mounts. In
der Gummielemente zu berücksichtigen. Die Kupplung such installations it is normal to set the engine some
läuft also zumindestens anfänglich mit einem gewollten millimetres high to offset settlement. The mounting
Radialversatz. Wegen dieses relativ großen Versatzes, supplier should advise the expected settlement figure
aber auch wegen der Schwierigkeit, den gewünschten to enable the installation to be adjusted. This
Versatz gezielt einstellen zu können, werden bei adjustment will mean that the coupling will have a
derartigen Anlagen die Ausrichttoleranzen higher radial displacement initially and this has been
entsprechend erhöht. considered as set out in the table.
S/R-A-2/3
Beispiel für starr aufgestellte Anlage: Example for rigid mounted engine plant:
Hochelastische VULKAN-Kupplung Größe RATO-S 2521 Highly flexible VULKAN coupling size RATO-S 2521
Radiale Ausrichtung - ohne eingebautes elastisches Radial alignment - without installed flexible part.
Teil.
R2 R1 237,6 236,1
'R12 0,75 mm
2 2
R3 - R4 236 ,0 237 ,5
'R34 0 ,75 mm
2 2
2 2
'R R12 R34
'R 0 ,75 2 0 ,75 2 1,06 mm
Dieser Wert ist größer als die empfohlene This value exceeds the recommended tolerance in
Ausrichttoleranz in der Tabelle, deshalb muß mit den table. Therefore it is necessary to coordinate the
Erstellern der Anlage eine Abstimmung über die resulting loads in the connected surface planes with the
resultierenden Belastungen in den Anschlußebenen builders of the system.
erfolgen.
S/R-A-3/3
Axiale Ausrichtung-ohne eingebautes elastisches Teil. Axial alignment - without installed flexible part.
X a1 X a2 X a3 X a 4 91,2 91,4 91,6 91,0

'X a Xa 90 1,3mm
4 4
Dieser Wert ist größer als die empfohlene This value exceeds the recommended tolerance in the
Ausrichttoleranz in der Tabelle, deshalb muß mit den table, therefore it is necessary to coordinate the
Erstellern der Anlage eine Abstimmung über die resulting loads in the connected surface planes with the
resultierenden Belastungen in den Anschlußebenen builders of the system.
erfolgen. .
Für elastisch aufgestellte Anlagen und komplett For flexible mounted systems and completely mounted
montierte Kupplungen kann die axiale Ausrichtung nur coulings, the axial alignment can only be checked over
über die Gesamteinbaulänge "L1"- NICHT am the complete installation length of the coupling "L1" and
Membranpaket - kontrolliert werden. NOT at the membrane package.
Die radiale Ausrichtung kann mittels Meßuhr am The radial alignment can be checked by means of a
Außendurchmesser des Spannringes kontrolliert wer- measurement gauge at the outer diameter of the
den. clamping ring.
S/R-A-4/3
Winklige Ausrichtung - ohne eingebautes Angular Alignment - without installed flexible part
elastischesTeil
X w 2 X w1 90,4 90,2
'X w1,2 0,10 mm
2 2
X w3 X w 4 90,0 90,6
'X w 3,4 0,30 mm
2 2
2 2
'X w X w1,2 X w 3,4
'X w 0,10 2 0,30 2 0,32 mm
Der Winkelversatz ist in Ordnung, da er unter dem The angular displacement is correct as it is below the
gemäß Tabelle 1 zulässigen Wert liegt. permissible value in the table 1.
S/R-A-5/3
Criteria for the inspection of
VULKAN-RATO-S/R couplings
The outer surface of a rotating coupling is continuously in contact with the surrounding air. This
ensures a good ventilation of the coupling but also gives rise to permanent contact with oxygen,
ozone and especially aggressive exhaust gases. This, in combination with the temperature, humidity
and UV-radiation, causes irreversible changes in the material structure at the rubber surface. This
unavoidable process is generally known as AGEING.
Due to the fact that AGEING is a combination of various influences it is impossible to simulate under
laboratory conditions. VULKAN has therefore examined RATO elements, with a long operational
life, to investigate the influence of AGEING on the operational-safety of the coupling.
The results of these investigations can be summarized as follows.
Due to the constructional design of the elements, and the different types and values of stresses, the
elements will, after a certain period of service, show indications of having undergone operational
service. The most frequent symptoms are:
1. Permanent set
Figure 1 S Figure 2
To determine the permanent set of a RATO-S segment the dimension „s“, measured at the outer
diameter of the rubber element, is determined (figure 1). The permanent set „s“ of a RATO-R
element can be measured through the deformation of the rubber roll (figure 2).
If the permanent set „s“ exceeds the criteria in the following table, the flexible parts must be
replaced; otherwise the flexible parts are suitable for further service provided there are no other
indications of a damage.
Criteria for inspection S/R-CRIT-1/1a

Modificatio 3
15.11.2006
Permissible permanent set for a RATO-S segment
Size S [mm] Size S [mm]
G 0310 65 G 3910 71
G 0510 77 G 4010 71
G 0810 92 G 4310 75
G 1210 22 G 4410 75
G 1310 24 G 4510 129
G 1410 26 G 4610 41
G 1510 27 G 4710 94
G 1610 30 G 4810 94
G 1710 32 G 4910 44
G 1910 34 G 5010 100
G 2110 37 G 5110 100
G 2310 39 G 5310 155
G 2510 43 G 5410 48
G 2710 43 G 5510 107
G 2910 46 G 5610 107
G 3010 53 G 5810 103
G 3110 53 G 6010 52
G 3210 56 G 6210 117
G 3310 56 G 6310 117
G 3410 59 G 6510 56
G 3510 59 G 6810 139
G 3610 66 G 7010 60
G 3710 66 G 7310 147
G 3810 109
It is advisable to determine and eliminate the reasons for the permanent set, that
is in excess of the permissible values given in the table, before renewing
elements.

Modificatio 3
15.11.2006
Permissible permanent set of one RATO-R element
Size S [mm]
4010 34
4910 39
5410 51
5710 48
6010 60
G 1610R 31
G 1710R 33
G 1910R 35
G 2110R 39
G 2310R 41
G 2410R 22
G 2510R 46
G 2610R 50
G 2710R 49
G 2730R *) 32
G 2910R 52
G 2930R *) 34
G 3110R 59
G 3210R 69
G 3310R 68
G 3330R *) 41
G 3430R *) 44
G 3510R 44
G 3810R 53
G 3910R 88
G 4710R 94
2
3-row elements
It is advisable to determine and eliminate the reasons for the permanent set, that
is in excess of the permissible values given in the table, before renewing
elements.

Modificatio 3
15.11.2006
2. Cracks
„AGEING“ gives rise to a hardening of the surface rubber. Due to the reduced elasticity at the outer
surface, cracks can be formed when the elements are deformed during service. Cracks (X/Y) with a
depth LESS than the permissible value are acceptable (figure 3, figure 4).
Figure 3 Figure 4
According to our experience, for a RATO-S/R flexible part cracks with a depth up to 5 % of the radial
rubber thickness are to be considered acceptable if they occur around the whole surface (figure 3,
depth X).
If cracks are predominantly in the outer rubber surface including the radius area, an equivalent
crack depth up to 8,5% of the radial rubber thickness is acceptable (figure 4, depth Y, Z).
If cracks are predominantly on the front side of the segments, a depth of 8,5 % of the radial rubber
thickness is acceptable as well (figure 4, depth Y).
Cracks should be ground out as soon as possible. This procedure, usually used for steel cast
components, can also be used for rubber elements.

Modificatio 3
15.11.2006
Permissible crack depth of a RATO-S coupling
Dimension Depth X Depth Y Depth Z Dimension Depth X Depth Y Depth Z

Group [mm] [mm] [mm] Group [mm] [mm] [mm]
G 0310 9,5 16,0 42 G 3910 15,0 25,5 66

G 0510 11,0 19,0 49 G 4010 15,0 25,5 66
G 0810 13,0 22,0 57 G 4310 16,0 27,0 71
G 1210 4,3 7,3 19 G 4410 16,0 27,0 71
G 1310 4,7 7,9 21 G 4510 18,0 30,5 77
G 1410 5,0 8,5 22 G 4610 18,0 30,5 77
G 1510 5,5 9,5 24 G 4710 18,0 30,5 77
G 1610 6,0 10,0 26 G 4810 18,0 30,5 77
G 1710 6,5 11,0 28 G 4910 19,0 32,5 83
G 1910 7,0 12,0 30 G 5010 19,0 32,5 83
G 2110 7,0 12,0 33 G 5110 19,0 32,5 83
G 2310 8,0 13,5 36 G 5310 20,0 34,0 90
G 2510 9,0 15,5 38 G 5410 20,0 34,0 90
G 2710 9,5 16,0 42 G 5510 20,0 34,0 90
G 2910 10,0 17,0 45 G 5610 20,0 34,0 90
G 3010 11,0 19,0 49 G 5810 22,0 37,5 97
G 3110 11,0 19,0 49 G 6010 22,0 37,5 97
G 3210 12,0 20,5 52 G 6210 23,0 39,0 103
G 3310 12,0 20,5 52 G 6310 23,0 39,0 103
G 3410 13,0 22,0 57 G 6510 24,0 41,0 105
G 3510 13,0 22,0 57 G 6810 25,0 42,5 111
G 3610 14,0 24,0 61 G 7010 25,0 42,5 113
G 3710 14,0 24,0 61 G 7310 28,0 47,5 125
G 3810 15,0 25,5 66

Modificatio 3
15.11.2006
Permissible crack depth of a RATO-R coupling
Dimension Depth X Depth Y

Group [mm] [mm]
4010 3,1 5,2

4910 3,1 5,3
5410 2,6 4,5
5710 3,8 6,4
6010 4,7 8,0
G 1610R 5,9 10,0
G 1710R 6,4 10,8
G 1910R 6,8 11,6
G 2110R 7,4 12,6
G 2310R 8,0 13,6
G 2410R 8,9 15,1
G 2510R 8,6 14,6
G 2610R 9,3 15,8
G 2710R 9,3 15,8
G 2730R 9,6 16,3
G 2910R 10,1 17,2
G 2930R 10,4 17,7
G 3110R 10,9 18,5
G 3210R 11,8 20,1
G 3310R 11,8 20,1
G 3330R 12,1 20,5
G 3430R 13,4 22,7
G 3510R 12,9 21,9
G 3810R 15,1 25,6
G 3910R 15,1 25,6
G 4710R 17,9 30,4
* Cracks in the area of the outer diameter / inner diameter free from cracks

Modificatio 3
15.11.2006
2.1 A guidance for VULKAN-RATO-S/R couplings:
x Cracks should be ground out as soon as possible. This can be done by a VULKAN
service engineer, or by the operator using the working instructions for „grinding“, refer
to section 2.3.
x When a crack is noticed, the depth and length must be marked in order to monitor it.
x It is important to check if the installation is operating / or has operated abnormally.
x In many cases the coupling acts as an indicator of installation malfunctions. When no

system malfunction can be determined, the couping has to be checked at shorter
intervals.
x When the cracks formed are due to an overloading of the coupling and this is not
corrected, the crack will continue to grow.
x An „unique event“ can damage the coupling. This, however, does not infer, that when
the installation operates „normally“ that the damage situation will not get worse.
x If the crack depth exceeds the permissible depth, we recommend replacing the re-
levant row as soon as possible.
2.2 Interval for checking RATO couplings:
x When, after checking a RATO coupling, surface cracks have been found which have
a depth LESS than the maximum value given in the table, a „2nd measurement“ of the
crack dimension should be made at an interval of about 3 months in order to check
crack growth.
x Assuming that the coupling itself is subjected to permissible load levels, the crack can
be defined as being the result of AGEING, when the crack dimensions do not
significantly change in the interval between the tests. Subsequent checks every 6
months can be made.
x After a system „unique-occurance“, cracks can appear in couplings that normally

operate within their permissible limits. The reason for the malfunction must be
investigated and corrected. A check should be carried out after 3 months or in case of
a new system malfunction.
x If a crack reaches the permissible depth, the respective element have to be restored.
Actions to be taken: Grinding off the cracks and applying of Coating LP.
Details: see 2.3.
x If cracks reoccur, repeat step 2 twice.

The element must however be replaced as soon as possible.

Modificatio 3
15.11.2006
2.3 Working instruction „grinding“
This working instruction is one component of the criteria for the inspection of RATO-S/R
couplings. The rework of the cracks in the rubber of the segments/elements can be done with
a suitable belt grinder.
Belt grinders are available in specialist shops as electric and pneumatic belt grinders. The
abrasive belts are available in three different coarseness (fine, medium, rough).
When grinding you should take care that the temperature is not too high at the final end of the
grinding procedure and the material rubber not hardened.
The moulding of the cracks should be, if possible, very accurately rounded and should not
show sharp corners.
During and after grinding it is not allowed to use French chalk or similar substances to
smooth the surface. A subsequent treatment with the system COATING LP
requires clean, fat-free and oil-free surfaces.
Subsequently the machined surface as well as the surface of the flexible elements must
be treated with COATING LP.
Advice concerning this treatment is given in document S/R/DS/DG-COAT-1/1 - 7/1.
The surface protection “COATING LP” should be checked during normal

engine maintenance intervals.
In case separation or cracking occurs again it can be repaired or has to be renewed
according to above described procedure.
The following photos show tools and reworked segments.

Modificatio 3
15.11.2006
Photo 1: Grinding tools
The rework of the cracks can be done with a suitable belt grinder. The abrasive belts are
available in three different grades of coarseness (fine, medium, rough).
Photo 2:

Modificatio 3
15.11.2006
Photo 3: Segment corners reworked
Photo 4: Additionally protection of the surfaces with "Coating LP"

Modificatio 3
15.11.2006
Surface Protection
VULKAN Coating LP
for
VULKAN RATO- S/R/DS/DG Couplings
In the event of a service call the surface of the flexible element must be provided with
VULKAN Coating LP, a protective coating made of a liquid elastomer. This elastomer
provides increased protection against environmental influences, especially against exposure
to oxygen, which causes aging of the near-surface zones of coupling elements. VULKAN
Coating LP consists of a single component.
The external surface of each segment of RATO-S couplings is coated, including the radius
transitions. It is not necessary to remove the segments.
The entire external rubber surface of RATO-R couplings is coated.
For RATO-DS/DG couplings, the elements must be removed for the treatment of all element
surfaces.
Instructions for application of

VULKAN Coating LP
For the treatment of surfaces of highly flexible elements, which have been sanded crack-free
according to the assessment criteria as a result of inspections, the following instructions
apply.
1.) The surfaces of highly flexible elements should be sanded with a belt sander on
the entire surface for optimum preparation.
This special surface treatment guarantees optimum cleaning and simultaneously
removes any micro-cracks.
1a.) For well-preserved surfaces, sufficient cleaning can be achieved by careful brushing
with a brass brush.
2.) Thorough cleaning of sanding dust from the surfaces is achieved by means of
compressed air. To keep the surfaces dry and free of grease, the compressed air
must be free of oil and condensates.
3.) The first coat is applied using VULKAN Coating LP. The drying time is ca. 30
minutes.
4.) The second coat is also applied using VULKAN Coating LP.
All coats should be thin but should cover the surface completely.
Surface protection VULKAN Coating LP S/R/DS/DG-Coat-1/7

Herne, 03/07/2007
Vulkancoating Lipren_EN.doc
The waiting time before re-commissioning the coupling is at least one hour after
application of the last coat.
VULKAN Coating LP can be stored for 6 months in closed cans.
Observe the safety regulations according to Safety Data Sheet 91/155/EG.

Herne, 03/07/2007
Safety Data Sheet (91/155/EG)
VULKAN Coating LP
Valid from: 07/03/2007
Supersedes version of: NEW
Printing date: 07/03/2007
1 MATERIAL/PREPARATION AND COMPANY NAME

DESIGNATION OF MATERIAL / OF PREPARATION
1.1 VULKAN Coating LP Lipren

Company name:
Heerstr. 66
D - 44653 Herne
Emergency telefone number
0049-2365-49-2232
2 COMPOSITION / INFORMATION ON INGREDIENTS
Chemical characteristics:
Aqueous dispersion of a polymer consisting of polychlorbutadienes.
Concentration: ca. 32 – 58 %.
Other information:
The starting material of the polymer is listed in EINECS.
3 POSSIBLE HAZARDS
See Chapter 8.
No hazard designation.
4 FIRST AID MEASURES
GENERAL INFORMATION:
Remove contaminated or saturated clothing.
AFTER SWALLOWING:
Consult a physician.
AFTER CONTACT WITH SKIN:
Wash immediately with water and soap.
AFTER CONTACT WITH EYES:
Rinse immediately with plenty of water; obtain medical advice, if necessary.

Herne, 03/07/2007
5 FIRE-FIGHTING MEASURES
SUITABLE EXTINGUISHANTS:
Product is not flammable when moist. For fire in surrounding area: water spray,
foam CO2, extinguishing powder.
SPECIAL HAZARDS IN FIRE-FIGHTING:
Product-specific, hazardous smoke gases in case of fire: hydrogen chloride.
SPECIAL SAFETY GEAR:
Wear atmosphere-supplying respirator.
6 MEASURES IN THE EVENT OF ACCIDENTAL RELEASE
ENVIRONMENTAL MEASURES:
Take precautions to prevent the product from entering the sewage system.
PROCEDURE FOR CLEANING:
Absorb with liquid-binding material (e.g. sand, universal binder, silica gel, acid
binder, sawdust).
Place in a suitable container.
Dispose of in accordance with regulations.
7 HANDLING AND STORAGE
HANDLING:
INSTRUCTIONS FOR SAFE HANDLING:
Avoid contact with eyes and skin.
Application, processing: Provide for adequate ventilation or exhaust.
INFORMATION ON FIRE AND EXPLOSION PROTECTION:
Normal measures for fire prevention.
STORAGE:
REQUIREMENTS FOR STORAGE ROOMS AND CONTAINERS:
Keep containers closed tightly.
Store in a cool place; maximum storage temperature: < 40°C.
Protect from frost.
STORAGE CLASS:
12 – Non-flammable fluids

Herne, 03/07/2007
8 EXPOSURE LIMITATION AND PERSONAL PROTECTIVE GEAR
COMPONENTS WITH WORKPLACE-RELATED CRITICAL VALUES TO BE

MONITORED:
2-Chlorbuta-1,3-diene CAS: 126-99-8

EG-No.: 204-818-0
MWC: (TRGS 900)
Critical values 5 ppm
18 mg/m3
Momentary value 4
Critical values Skin designation: (TRGS 900)
Can be absorbed by the skin.
TECHNICAL PROTECTIVE MEASURES

For latex processing (e.g.: drying): Provide for adequate ventilation or exhaust.
PERSONAL PROTECTIVE GEAR:

RESPIRATORY PROTECTION:
In the event of dust/vapours/aerosols or if critical values are exceeded (e.g. MWC):
Use respiratory filter unit with suitable filter (filter type AX) or wear atmosphere-
supplying respirator.
HAND PROTECTION:
Rubber gloves.
EYE PROTECTION:
Safety goggles.
HYGIENE:
Remove contaminated or saturated clothing.
Avoid contact with eyes and skin.
Do not breath vapours or aerosols.

Herne, 03/07/2007
9 PHYSICAL AND CHEMICAL PROPERTIES
APPEARANCE:
FORM:
Liquid
COLOUR:
Milky white
ODOUR:
Faint
SAFETY-RELATED DATA:
pH VALUE
ca. 13 (20°C)
MELTING POINT/MELTING RANGE

ca. 0°C
BOILING POINT/BOILING RANGE:

ca. 100°C (1013 hPa)
FLASH POINT:
Not applicable
IGNITION TEMPERATURE:
Not applicable
UPPER EXPLOSION LIMIT:

Not applicable
VAPOUR PRESSURE:
ca. 23 hPa (20°C)
Water
DENSITY:
ca. 1.075 – 1.13 g/cm³ (20°C)
WATER SOLUBILITY:
Dilutable
VISCOSITY, DYNAMIC:
ca. 1.0 – 150.0 mPas (20°C)

Herne, 03/07/2007
10 STABILITY AND REACTIVITY
HAZARDOUS REACTIONS:
No hazardous reactions known.
HAZARDOUS BY-PRODUCTS:
By-products in the event of thermal decomposition: hydrogen chloride.
11 TOXICOLOGY
SKIN IRRITATION:
Frequent or prolonged contact can cause irritation.
ADDITIONAL INFORMATION:
This information is based on the pH value.
12 ECOLOGY
INFORMATION ON ELIMINATION (PERSISTENCE AND DEGRADABILITY):

Physical-chemical elimination: The product can be eliminated from water through
abiotic processes, e.g. adsorption on activated sludge.
13 DISPOSAL
PRODUCT:
Dispose of in compliance with the local regulations, e.g. in a suitable incineration
plant.
No waste code has been defined for this product in accordance with the European
Waste Catalogue.
14 TRANSPORT
TRANSPORT / ADDITIONAL INFORMATION:

Not a hazardous substance according to transport regulations.
15 REGULATIONS
LABELING IN ACCORDANCE WITH EC DIRECTIVES:

Legal basis: The product is not subject to labelling requirements according to EC
directives (1999/45/EG).
NATIONAL REGULATIONS:
EMERGENCY MANAGEMENT ORDINANCE:
Not listed in Appendix I (Emergency Management Ordinance 2000).
WATER HAZARD CLASS:
WHC 1 – slightly hazardous to water, code number: 662
16 OTHER INFORMATION
The information is based on the current status of our knowledge and experience.
However, it does not constitute an assurance of product qualities or a contractual legal
relationship.
DATA SHEET ISSUED BY:
Vulkan Kupplungs- und Getriebebau B. Hackforth GmbH & Co. KG, Herne

Herne, 03/07/2007
Engine Adjusting Valve C5.05.13.09.15.00
-
Engine Adjusting Valve
en / 22.11.2000 FD020145 1/10

Electrically Operated MOV - 81
Control Valves
Electrical Motor Drive
MOV - S - 81
MOV - 3 - 81
Types Technical Data
Single-seat valve in straight-way form Overall length: according to DIN 3300
Type MOV-81
Dimension sheet EK-413 Flanges: PN 10 DIN 2532
PN 16 DIN 2533
Seat valve in straigth-way form PN 25 DIN 2544
with noise attenuating cone PN 40 DIN 2545
Type MOV-S-81
Dimension sheet EK-413 Operating pressures: according to DIN 2401
Three-way valve
Type MOV-3-81 Differential in accorddance with tables
Dimension sheet EK-414 pressures: EK-413 and EK-414
Positioning ratio: 1:50

Construction
Positioning - normal
Straight-way valves up to DN 200 with shrunk seats, beginning speed: 25mm/min; 50mm/min possible
with DN 250 with screwed seats
cone characteristics linear or equi-percentage different Kv values Strokes: DN 15- 50 25 mm
are possible at equal nominal width DN 65- 100 35 mm
DN 125-175 50 mm
three-way valves with screwed-in double-seat bushes with linear DN 200 58 mm
characteristics of flow and disk cones DN 250-350 65 mm
inserted stuffing-box flanges
Installing position: vertical to horizontal
cast housing
driven by spur gearing with linear actuator Electrical data: according tables „electrical Drive Data“
4 drive sizes, having different positioning forces are available

Additional Equipment
E-motors for 50 or 60 HzAC and three-phase voltages
Soft seal in the cone
drives with emergency manual operation and mechanical cone with multi-hole sleeve
position display
ribbed stuffing-box
drive covered with steel cover spindle sealing by bellows W. No. 1.4571
General
The motor valves are used as electrically operated continuous
Materials control elements (control valves) and as on-off controller for the
control of gaseous and liquid agents. The control is established
Valve housing: PN10/16 GG20 by means of two-point or three-point controllers as a function of
PN25/40 GS-C-25 temperature, pressure, quantity etc. or manually with push-
othermaterials, such as special steel cast, button or switch.
chromium-nickel steel, gun metal, bronze,
etc. and hard rubber lining on request
Construction and Operation
Valve seats: W. No. 1.4401
for three-way valves DN 65-200 -Straight-way valves in single-seat construction.
W. No. 1.4410 or bronze G Sn Bz 10 Dimension sheet EK-413
other materials on request with cooling rib assembly or bellows sealing, respectively.
Dimension sheet EK-425
Valve conel: W. No. 1.4401
for straight-way valves DN 125-350 - Three-way valves.
and three-way valves DN 250-350 Dimension sheet EK-414
W. No. 1.4410 or bronze G Sn Bz 10 with cooling rib assembly or bellows sealing, respectively.
other materials on request Dimension sheet EK-419
Valve spindle: W.-Nr. 1.4401 or bronze AlBz 10Ni
other materials on request - 4 different drives (1.2 kN; 4.5 kN; 12 kN; 24 kN) are optionally
available to meet the operational requirements.
Stuffing-box PTFE, silkyam (reinforced)
packing: orpure graphite The switching-off at the end position is established for
straightway valves in the closing position torque-dependent,
Housing: steel casting GS-C-25 and in
the opening position travel dependent, with an additional limit Electrical and technical drive data
switch, being torque dependent, wired in parallel, for three-way
valves in both end positions, torque dependent. Data for The motors are designed for intermittent
regulating duty S4 acc. to VDE 530 with a relative
In addition, a further free travel dependent limit switch with operation: duty cycle of 30%.
switch-over contact is provided. switching frequencymax.600/h
The valve position is indicated by a pointer at the drive spindle minimum pulse duration: 250 ms
and a scale at the housins. minimum pulse pause: 40ms
For the analog remote transmission of the valve position, the Electrical at the terminal via cable sorewings
installation of 2 potentiometers is possible. wiring: according to DIN 89280
In addition, a further travel dependent limit switch can be Power supply: normally
installed. The built-in electro motor (a) drives the linear actuator 230 V- 50 or. 60 Hz, single-phase-AC,
via a spur gear. In the last gear (b) of the geartrain, a bushing with or
internal thread is shrunk in, which runs in ball bearings. In this 380 V- 50 or. 60 Hz three-phase current
thread runs the upper part of the push-rod (d), provided against other supply voltages on request
torsion by a key and groove. Type of protection: DIN 40050 · IP 65
When the gear is driven, the push-rod and the valve spindle Allowable ambient temperature: - 20 to + 60°C
performs a push / pullmotion, depending on direction of rotation.
Limit switch: torque dependent switches max. 230 V
On power failure, the final control element can manually be ohmic loadmax.10A
actuated. inductive loadmax.5A
The gear ist dustproof separated from the electrical components travel dependent switchesmax.230V
in an aluminium pressure housing. Terminals, motor, limit switch ohmic loadmax.5A
and potentiometers are easily accessible by removing of the inductive loadmax.3A
steel cover electric bulb max. 1 A
Potentiometer: max. 50 V, 100 mA
Motor data
Positioning time mm/min 25 50 25 50 30 60
Voltage Volt
single-phase
three-phase three-phase
AC current
400 V 50 Hz 440 V 60 Hz
230 V 50 Hz
Drive 1,2 kN
Rated current mA 29 15 14,3
Power consumption Watt 6,6 9,9 9,35
Power output Watt 2,4 3,1 3,1
Rotational speed motor U/min 500 500 600

Voltage Volt
single-phase
AC current
400 V 50 Hz 440 V 60 Hz
Drive 4,5 kN 230 V 50 Hz
Rated current mA 135 160 110 80 100 100
Power consumption Watt 28 32 35 32 35 45
Power output Watt 5,3 12 10 16 12 19
Rotational speed motor U/min 1350 2700 1350 2700 1620 3240

Voltage Volt
single-phase
AC current
400 V 50 Hz 440 V 60 Hz
Drive 12 kN 230 V 50 Hz
without brake Rated current mA 320 700 210 290 220 265
Power output Watt 22 72 28 63 28 85

Voltage Volt
single-phase
AC current
400 V 50 Hz 440 V 60 Hz
Antrieb 24 kN 230 V 50 Hz
without brake Rated current mA 660 930 400 700 342 640
Power output Watt 67 110 75 215 88 235
Connection Diagrams The pipes have thouroughly to be cleaned prior to assembling,
in order to prevent a later damage to the seats and cones.
AC 2/2 way valve RTA-264
3/2 way valve RTA-265 The installation of a dirt tr,ap in front of each control valve is
strongly recommended.
Three-phase 2/2 way valve
current: linear actuator 1,2 + 4,5 kN RTA-264/3 On mounting of straight-way and angle valves pay attention to
linear actuator 12 + 24 kN RTA-264/4 the direction of arrow on the valve housing.
3/2 way valve Mix and partitioning valves are provided with the figures 1,2 and
linear actuator 1,2 + 4,5 kN RTA-265/3 3 on their connecting flanges. Observe the correct installation in
linear actuator 12 + 24 kN RTA-265/4 accordance with piping diagram.1 is always the joint
connection, whereas to 2 and 3 the incoming or leaving part
Installation streams are connected.
"These actuator valves shall be mounted with the drive towards The wiring and connecting of the electrical circuitry has to be
the top. For any other position ask before ordering." performed in accordance with the regulations for the installation
of power plants and with the respective wiring diagrams.
Start-up and
Adjustment instructions
For start-up of the valve place the drive by means of the hand
wheel (e) in the middle of the positioning travel, switch on power
and give shortACpulses to the drive; watch whether the push rod
(d) moves into the correct direction. Otherwise, exchange the
motor connections at the terminal strips 2 + 3.
Drive 1.2 kN and 4.5 kN

Operate manually only with the motor at standstill.
For this purpose press the bolt (f) mounted below at the drive
housing with the hexagonal head into the housing until the spring
lever (h) engages into the notch of the bolt. Hereby rotate the
handwheel (e) a little bit. On rotating of the handwheel ciockwise,
the push spindle is extended rotating ccw draws the spindle in.
On pressing of spring lever (h) in the direction of the valve shaft
the bolt jumps out on its own and the drive is switched back to
motor drive.
Drive 12 kN and 24 kN
Change over to hand-operating:
Push hand disengaging lever into direction -1- (at the time turn
hand wheel slightly if necessary), then swivel hand disengaging
lever above the hexagon screw into direction -2-.
Now hand operating position is locked.
Change over to motor drive:
Swivel hand disengaging lever into direction - 3 - and release. All

further engaging proceedings will occur automatically with
starting up of themotor.
Figure travel dependent switch and message devices
With the end position reached with extended push spindle, the
two slotted levers (1) are parallel. A'ter loosening of the nut, the
carrier bolt (7) can be moved into the slot of the lever allowing the
stroke of the drive to be adjusted by means of the auxiliary scale.
After this being done, re-fasten the bolt. In this position, the
potentiometers (5) (in case there are any) have to be in the end
position. They can be adjusted by rotating the slider.
After that move the drive by the required travel for 2/2 valves or
the possible travel for 3/2-way valves in the opposite direction the
potentiometer will then turn into the other end position.
For the adjustment of the travel dependent limit switch "S 3" for
the limiting of the travel in the position open, the knurled head nut
(4) has to be loosened. Adjust the cam washer (4) to make the
switch shut off. The second built-in travel dependent switch "S 4"
and another possible "S 5" may freely be adjusted inbetween the
two end positions. Re-fasten the knurled head nut after the
switches being adjusted.
The switches provided for the end positioning are factory
adjusted. The torques of the load dependent switches are fixed
and can not be changed.
1 Slotted levers; the lower one is marked for the set travel
2 Travel-dependent switches
3 Knurled nut
4 Cam disks
5 Potentiometer for position indication
6 Scale for setting the travel
7 Connection bolt
Maintenance
Valve assembly Drive

Re-fasten the screws and flange connections at the housing after Grease the drive at normal operating conditions every three
start-up of the installation as the sealings are settling a bit at the years, at higher loads after approx. 200 000 double strokes with
beginning. The maintenance of the stuffing-box is also important. "Fett Klüber Structoris P 00" or a similar grease.
In case of leakage, the stuffing-box gland has to be fastened at
once. If this is no longer possible, the stuffing-box has to be re-
packed.
Take care to use the right material, depending on the agent, the
temperature etc. Keep the part of the spindle being in contact with
the stuffing-box always clean and grease at regular intervals with
a suitable grease. If the sealing surfaces at the seat and the cone
are damaged by dirt or foreign particles, no longer giving a tight
seat, they can be ground with a fine emery paste. With valves
having PTFE inserts in the cone, the latter can easily be replaced.
The above information and our technical advice for application in word, in writing and by tests
are given to the best knowledge. They shall be applied, however, only as hints without
obligation, also with reference to any protective rights of third parties. The advice does not
relieve you from examining our advisory hints and our products by yourself with regard to their
suitability for the intended procedures and purposes. Application and use of our products and
those products manufactured by you on the basis of our technical advice for application are
beyond our possibilities of control and, therefore, exclusively belong to your responsibility. The
sale of our products is subject to our General Terms and Conditions of Sale and Delivery.
Ausgabe/EDITION 06/02
Pleiger Maschinenbau Postfach 32 63 ( +49 / (0) 2324 398-0

GmbH & Co KG D-58423 Witten Fax +49 / (0) 2324 398-380
Ambiguous Document References X0
en / 23.09.2008 QV020011 1/8

Please select target document for A5.05.05.09.06.nn

-------------------------------------------------------------------------------------------------------------------------------
• A5.05.05.09.06.00
• A5.05.05.09.06.01
en / 23.09.2008 QV020011 2/8

Please select target document for A5.05.08.05.01.nn

-------------------------------------------------------------------------------------------------------------------------------
• A5.05.08.05.01.01
• A5.05.08.05.01.02
en / 23.09.2008 QV020011 3/8

Please select target document for B1.05.02.9.2601

-------------------------------------------------------------------------------------------------------------------------------
• B1.05.02.9.2601 EE
• B1.05.02.9.2601 FF
en / 23.09.2008 QV020011 4/8

Please select target document for A3.05.nn

-------------------------------------------------------------------------------------------------------------------------------
• A3.05.00
en / 23.09.2008 QV020011 5/8

Please select target document for B1.05.10.n.861n

-------------------------------------------------------------------------------------------------------------------------------
• B1.05.10.9.8610 PP
• B1.05.10.9.8618 DD
en / 23.09.2008 QV020011 6/8

Please select target document for B1.05.06.9.72n0

-------------------------------------------------------------------------------------------------------------------------------
• B1.05.06.9.7210 MM
• B1.05.06.9.7220 SS
• B1.05.06.9.7240 SS
• B1.05.06.9.7250 ZC
en / 23.09.2008 QV020011 7/8

Please select target document for B1.05.08.9.641n

-------------------------------------------------------------------------------------------------------------------------------
• B1.05.08.9.6410 HH
• B1.05.08.9.6414 AA
• B1.05.08.9.6417 VV
en / 23.09.2008 QV020011 8/8

Engine Operation Instruction(Vulkan)

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Engine Operation Instruction(Vulkan)

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Flange - Coupling - RATO C5.05.12.13.02.

Flange - Coupling - RATO

en / 23.09.2008 FD038287 1/41

Highly-flexible VULKAN - RATO – R Couplings

Dimension Group: G322TR

Drawing No.: 1G3220R053

Partslist No.: 1G322TR053

VULKAN Kupplungs- und Getriebebau

Technical Data RATO-R-322T

Flexible Part, Drawing EG3220000R

Delivery Condition AG3220R053

InstallationandOperating Instructions E&B RATO_R_with Bushes G2120_G3120, G3220 a.

Aliment Instructions for highli flexible

Criteria for the inspection of

Surface Protection COATING LP for

The guide lines in the RATO - catalogue

Manuf.Product: 1G322TR053-C Date: 23.06.2008

Item Quant Part Number Description Dimensions Material Remark DM

1 1 EG322T000R Flex. Part G322TR St/Gummi

3 1 4G33R0022M-C Connecting Ring FM 1386 X 905 X 94.1 S355J2G3

5 1 4G32K0033M-C Hub FM 540 X 188 X 278.1 42CrMo4+QT EN10083-1

16 64 7033620000 DISC 20 42CrMo4+QT EN10083-1

19 32 7000120100-C HEXAGON BOLT M 20 X100 10.9 931M

20 32 7001120040-C HEXAGON BOLT M 20 X 40 10.9 933M

22 24 7000130090-C HEXAGON BOLT M 30 X 90 10.9 931M

28 32 7020120000 HEX NUT M 20 10 934

29 32 7020020000 Hex Nut M 20 8 DIN934

35 24 7033630000 DISC 30 42CRMO4+QT EN 10083-1

36 24 7019130000 HEX NUT M 30 10 DINEN24032

40 12 7033612000 Disc FM 20 X 12.1 X 4.5 42CrMo4+QT EN10083-1

46 6 3G32K80000 BUSH FM 24 X 13,5 X 47 42CrMo4+QT EN 10083-1 EN 10083-1

47 6 7000112080 HEXAGON BOLT M 12 X 80 10.9 931M

48 6 7020112000 Hex Nut M 12 10 934

51 32 7010420100-C SOCK HD SCREW M 20 X100 10.9 912

52 32 7033620000 DISC 20 42CrMo4+QT EN10083-1

55 2 7042621080 DOWEL PIN FM 21H8 X 80 St50 K PASSUNG H8

Manuf.Product: EG322T000R Date: 23.06.2008

Item Quant Part Number Description Dimensions Material Remark DM

1 2 EG321TR000 FLEX.ELEMENT ST/GUMMI

2 30 7001120060-C HEXAGON BOLT M 20 X 60 10.9 933M

3 30 7020120000 HEX NUT M 20 10 934

4 90 7033620000 DISC 20 42CrMo4+QT EN10083-1

5 2 7005320060-C HEX FITTEDBOLT M 20 X 60 10.9 609 JS6

6 2 7020120000 HEX NUT M 20 10 934

7 6 7033720000 DISC 20 42CrMo4+QT EN10083-1

8 32 3G32K3000M-C Bush FM 45 X 21.5 X 40.35 42CrMo4+QT EN10083-1

E&B G2120R – G3120R

G3220 and G3820 series 2200

(membrane assembly with bushes)

VULKAN Kupplungs- und Getriebebau

Title Installation and Operating Instruction Subject RATO-R Standard Execution

1 General Safety Regulations .....................................................................................3

1.1 Symbol for industrial safety ......................................................................................3

1.2 Attention remark.......................................................................................................3

1.3 Safety regulations ....................................................................................................3

2 General information about the VULKAN RATO-R coupling .....................................3

3 Procedure before the installation .............................................................................4

3.1 Delivery condition of the RATO - R coupling............................................................4

3.2 Design of the flexible part.........................................................................................5

3.3 Difference between single-row and double-row coupling.........................................6

'R 0 ,75 2 0 ,75 2 1,06 mm

X a1 X a2 X a3 X a 4 91,2 91,4 91,6 91,0

'X w 0,10 2 0,30 2 0,32 mm