High Speed

Founded in Milan Italy in 1957, Transfluid hasalways been a point of reference in the world ofindustrial transmission equipment and thestandard that its competitors measure themselves. Fluid couplings, variable speed drives, brakes clutches, couplings and hydraulic transmissions constitute the core of the product line, while ultra-modern technology, careful selection of materials and meticulous assembly are the key ingredients in the recipe that has placed those products at the forefront of the market. Thousands of customers continue to choose Transfluid for the most diverse and demanding applications, knowing they can rely on Transfluid’s technical department, where design, engineering and planning experts are always on hand to quickly resolve client’s problems.Italian dynamic innovation, coupled with ongoingstaff development and more than fifty years ofhard-earned expertise, are the foundation of thecompany’s success.Transfluid’s unique approach has sparked smallbut important revolutions in the field of heavy-duty transmissions, for which recognition has come in the form of international awards.Transfluid’s catalogue boasts a wide range ofproducts, and each unit produced is tested forsafety, quality and durability. Being a world leaderin the design and manufacture of fluid couplings,Transfluid has earned a reputation for diligentservice, which assures the competence of theapplications through careful quality control andon-site technical assistance.In addition to the Italian Headquarter, Transfluid’s broad sales network consists of six branches located in Australia, China, France, Germany, Russia and United States, one representative office in Brazil and 32 distributors located throughout the world.

To meet the energy savings and reliabilitydemands modern industry expects, Transfluidhas developed two new lines of variable,high-speed hydraulic couplings, the KSL-HSand the KPTB-HS. Capable of input speeds of3600 rpm the HS family of couplings hasalready found demands in the power, steel,paper, cement, chemical and petrochemicalindustries. The high-speed products arefinding applications in boiler feed pumps, fans,blowers, pumps, compressors.With more than half a century of experience inthe field of variable speed drives, Transfluidis using its expertise to expand into thehigh-speed markets with the KSL-HS andKPTB-HS series of variable high-speed drives.

In centrifugal machines, such as pumps,compressors and fans, the speed control playsa crucial role in saving energy.As an example, by decreasing the drivingspeed of a centrifugal machine to 50% of itsnormal operating speed, the current draw ofthe driving electric motors is reduced to oneeighth of its normal draw.Therefore, in application or processes that donot require the centrifugal machine maximumoutput, the benefit of a variable speed drive iseasily realized through significant powersavings. This important variable speedfunction can be accomplished by installing avariable fill hydrodynamic coupling in the drivetrain. By controlling the volume of oil thatcirculates inside a variable speed coupling theoutput speed can be continuously changed tooptimize the driven machines performance.Traditionally controlling the oil volume isaccomplished via scoop tube, however,Transfluid has pioneer a solution based uponthe most current technology called flow control.The flow control variable speed hydrodynamiccoupling is based on a very simple principle.The power media (oil) is withdrawn from thetank by an electric feed pump and fed to thedriving and driven impellers of the couplingcircuit. The oil is removed by centrifugal forcethrough calibrated orifices on the perimeter ofthe circuit. The oil then returns to the tank bygravity. By varying the feed pump oil flow, thevolume of oil between the driving and drivenimpellers can be changed. The end resultis accurate control of driven machinesacceleration time and precise speed variation.Simple operation, standard and externallyaccessible maintenance components, makethe KSL-HS and KPTB-HS a simple, reliable,low maintenance, variable speed solution.

It is well know that speed control of centrifugalmachines provides significant economicadvantages compared to the use of valves ordampers. In applications that require a broadspeed range, valves and dampers drasticallyreduce the overall efficiency of the system.The features of KSL-HS and KPTB-HShigh-speed couplings combine a simple designwith the high efficiency of a hydraulic couplingto provide an optimal solution for centrifugalmachine design.Among existing variable speed technologiesthe two most common are the FrequencyInverter and the Hydrodynamic Couplings.Although inverter technology has made somesignificant advances, the HydrodynamicCoupling offers key advantages that cannot bereplaced by any other technology.

• A variable speed hydrodynamic couplingallows a motor to be powered directly fromthe main electrical circuit and operate at itsnominal speed. This allows for the use ofstandard motors that are more economical topurchase than those designed for use withvariable frequency drives.

• The important difference is that an inverterdriveline has is a permanent mechanicalconnection between the motor and the drivenmachine. A hydrodynamic coupling eliminatesthis connection allowing torque to be transmitedwithout damaging other mechanical partsfrom the torque spikes and torsionalvibrations. This extends the overall operationallife of the entire driveline.

• Hydrodynamic couplings are robust andreliable machines. Service can be doneby a qualified mechanic. In contrast, themaintenance of a frequency inverter is expensive due to the rapid and random failure of its components and its rapid obsolescence of

parts. Additionally, inverter repair requireshighly skilled, specialized, technicians andextended service times.

• A hydrodynamic coupling is installed in thedriveline, while a frequency inverter requiresa dedicated pressurized and air conditionedroom.

• Hydrodynamic Couplings are less expensivethen inverters. Additionally inverters requirespecial motors and at times the selection ofhigher rated motors.Transfluid HS couplings also offeradvantages compared to the traditional scooptube system. The scoop tube is a stationaryelement that is an obstacle to the oil inrotation, inducing a significant hydrodynamicresistance and decreased efficiency.A closed loop “feedback” is required to controlthe linear position of the scoop as it relates tothe output speed. When ordering, applicationrotation direction must be specified.Furthermore, major components such as thescoop and oil pump are integrated inside thecoupling housing making repairs difficult andtime consuming.

The Transfluid control flow system:

• is self-adjusting, since the draining of oilfrom the calibrated orifices depends on therotation speed of the outer impeller which isdirectly connected to the driven machine.This allows the coupling to stabilize its speedin the presence of load variations without theneed for corrective actions and “loop” control

• eliminates the stationary element (thescoop) and hydrodynamic resistance in theworking circuit

• operates in forward and reverse

• has all key accessories mounted externally,allowing for simple and inexpensivemaintenance.

Transfluid The speed variation

How it works

Benefits

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The seriesKPTB-HSThis high-speed speed drive is used primarilyin medium and low power applications, and isavailable in sizes 15 and 17 (these numbersrepresent the nominal diameters of theworking circuit in inches).These units are also available in LowTemperature and Explosion Proof versions.A simple design combined with greatreliability and performance makes thiscoupling a product with exceptional value.In addition, the KPTB-HS’s versatile designallows you to configure a machine according acustomer’s needs but still keep it within atight budget. Features such as Viton® sealsused throughout the drive and all main maintenance components externally mounted foreasy access add even more to this unit’s value.

KSL-HSThis high-speed drive is used primarily inmedium and high power applications, and isavailable in size 21 and 24.These units can be purchased with an optionalauxiliary lubrication system that supplies oilto the motor and driven machine bearings.Low Temperature and Explosion Proofversions are available as well. Features onthese units that provide durability and easeof maintenance are labyrinth seals, steelpiping, externally accessible maintenancecomponents, and horizontally split exteriorhousing (allows maintenance & repair withoutdisturbing alignment).

Today, KSL and KPTB couplings are installed inhundreds of applications worldwide providingits user with unsurpassed performance andreliability. Profiting from these experiences,the new HS series of hydrodynamic couplingshave been designed to work in most extremeconditions to ensure decades of reliable,economical and efficient service.

20 17

18

15

14

2

3

4

5

6

7 8 9 1 10 11

16

I

H

F

G

E

D

C

A

B

19

12

13

Feeding pump Thermostatic valve

Oil levelFeeding solenoid valve

Oil filter with differential pressure transducer Temperature gauge

Feeding pressure gauge Electrical panel for customer interface

Oil breather

Impellers groupFluid coupling variable flow feeding pump

Feeding filter with vacuum switchFeeding filter by-pass valve

Lubrication filter with differential pressure transducerFluid coupling lubrication pump

Feeding pressure gaugeTemperature gauge

Lubrication pressure gaugeOil temperature switch

Thermoresistance PT100Oil level

Manual control valveFeeding pump emergency manual control panel

Driven / driving machine bearings lubrication pumpDuplex filter group and lubrication oil pressure /

flow regulation valvesDriven / driving machine bearings lubrication oil pressure

Bearings lubrication oil from driven / driving machineOil level switch

Oil breather

Working scheme

TO MOTORSYSTEM

TO FLUID PUMPLUBE SYSTEM

INPUT SPEED

SENSOR

OUTPUT SPEED

SENSOR

MPCB - R5

12 - 24 Vdc

12 - 24 Vdc

DISPLAY

NODE...

NODE 1

NODE 2

1

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Variable flow feedpump with variable

frequency converterLubrication oil pump

Heat exchanger oil pumpPressure gauge

Pressure differential transducerBleeding orifices

Quick release valvesHeat exchanger

Oil level switch and gaugeMax temperature switch

Feed oil filterLub. oil filter

Vacuum switchPressure gauge

Temperature gaugeThermoresistance PT100

Speed sensorHeat exch. pump control

Manual flow control valvePressure switch (min. lub.)Oil breather

21 KSL-HS

MODELsize

MODELsize

940

1300

A

A

1500

1710

B

B

920

920

C

C

100

100

D

D

1900

2080

1500

E

E

700

700

G

G

2000 3600700

725

F

F

1600

MOTORPOWERkW

MOTORPOWERkW

SPEEDrpm

SPEEDrpm

WEIGHTw/o OIL

WEIGHTw/o OIL

3000

17 KPTB-HS

Without integrated auxiliary lubrification system

Without integrated auxiliary lubrification system

With integrated auxiliary lubrification system

MODELsize

770

A

800

B

636

C

75

D

1160

E

420 500

G

600 3600580

F

560

MOTORPOWERkW

SPEEDrpm

WEIGHTw/o OIL

3000

21 KSL-HS

24 KSL-HS

2000

3200

3600

3600

1600

2600

3000

3000

1700

2200

E

E

E

C

C

A

A

B

B

B

G

G

G

D

D

D

D

F

F

F

ITALYTRANSFLUID SRLVia Guido Rossa, 421013 Gallarate (VA)Ph. +39.0331.28421Fax +39.0331.2842911info@transfluid.it

AUSTRALIATRANSFLUID AUSTRALIA PTY LTDSmithfield NWS 2164Ph. +61.297572655Fax +61.297560181tfaustralia@transfluid.it

CHINATRANSFLUID BEIJING TRADE CO.LTD101300 BeijingPh. +86.1060442301-2Fax +86.1060442305tbtcinfo@transfluid.it

FRANCETRANSFLUID FRANCE s.a.r.l.38110 RochetoirinPh. +33.9.75635310Fax +33.4.26007959tffrance@transfluid.it

GERMANYTRANSFLUID GERMANY GmbHD-48529 NordhornPh. +49 5921.7288808Fax +49 5921.7288809tfgermany@transfluid.it

RUSSIATRANSFLUID OOO143100 MoscowPh. +7.495.7782042Mob. +7.926.8167357tfrussia@transfluid.it

U.S.A.TRANSFLUID LLCAuburn, GA 30011Ph. +1.770.8221.777Fax +1.770.8221.774tfusa@transfluid.it

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June 2015