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Manual - Castle Pumps

1. If the machine is not supplied with a base or lifting lugs use ropes The ropes must be placed around the machine and positioned in such a way as to ensure a balanced lift Do lift the machine with more weight the head that is with centre of gravity not immediately below the lifting point Make sure that the pump does not overturn and that it is handled in safety and in a stable position Vertical axis pumps must never be left in an upright position without adequate fixing Suspended load The machines must always and only be placed horizontally Do not lift the complete electropump by means of the motor or reduction unit lugs The lugs are intended solely for transporting the motor or the reduction unit Pag 16 02 02 2011 OMI EN PCP 001 R00 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps As the machine configurations are all very different the instructions given here are of a general nature but they do provide sufficient guidelines to ensure that qualified personnel handle the pump correctly If in doubt contact the supplier or request more detailed information concerning your specific machine When handling trailer mounted pumps Before moving the machine
2. OMI EN PCP 001 02 02 2011 Pag 9 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 5 5 Safety pressure relief check valves The Manufacturer recommends installing a suitable safety device on the pump delivery casing in order to prevent operating pressures from exceeding the pump specifications In addition a check valve should also be fitted on the pump delivery casing to prevent return flow If both valves are installed then the safety valve should be placed closer to the pump than the check valve 5 6 Dry run protection When the continuous product flow is not guaranteed it is advisable to use a special mechanism to protect the stator against dry running This protection prevents damage to the stator caused by loss of liquid One possible system involves the installation of a thermal probe connected to an electrical panel in the stator If the fluid does not arrive at the rotor the rubber of the stator overheats and the increased temperature acts on the electrical circuit and shuts off the motor this device can be fitted even after the pump has been installed Alternatively flow switches can be used to directly control product presence Other systems can be evaluated according to specific requirements 5 7 Drive Many different drives can be applied to progressive cavity pumps The most widely used combinations include electric motors hydraulic motors gearmotors vari
3. 56 2 3 6 Tandem double mechanical seal 0869 2 2224 4 1 enne nennt nne nnns ennt 57 Pag 4 02 02 2011 OMI EN PCP 001 ROO Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 3 SYMBOLS Danger warning Electrical hazard General warning indicating the potential risk of personal injury Electrical hazard indicating the potential risk of personal injury Danger suspended load Caution corrosive material Rotating parts hazard Do not remove safety guards from rotating parts Do not repair or oil machine whilst in motion This symbol draws your attention to the information Wear suitable clothing gt gt gt Wear protective gloves OMI EN PCP 001 02 02 2011 Pag 5 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 4 SAFETY 4 1 Failure to comply with safety standards 9 Failure to comply with the safety standards described this manual and those relating to common sense can cause danger to people and the environment and damage the machine Specifically such nonobservance can cause inability of machine and or plant to perform key functions damage to the machine and or plant electrical mechanical and or chemical danger to persons environmental danger due to leakage of hazardous substances Failure to observe and comply with these safety standards will invalidate the war
4. 17 EN 4L1 A NG 905 7 35 M 2 C MR 1 1KA 1011 AN 4K2 0040 2K4 45 56 8 64 601 B 1611 8 2 2011 206 10K2 EN T 0060 4K4 55 57 5 8 65 5 30L1 16K2 4011 201 20 2 0120 10K4 65 62 8 70 60L1 30K2 80L1 40K2 0300 20 4 10 2 2 y 2 2 120L1 60K2 SPARE PARTS LIST KEY RECOMMENDED REPLACEMENT FOR HIGH WEAR PART r RECOMMENDED REPLACEMENT FOR PART NOT SUBJECT TO WEAR OR HIGH WEAR POS Qty Description NOTES 200 1 MECHANICAL SEAL HOUSING 201 1 PLUG 202 1 MECHANICAL SEAL RING 203 1 MECHANICAL SEAL ROTATING PART STATIONARY PART 204 1 PIN 9 205 1 O RING R 206 3 GRUB SCREW 210 1 MECHANICAL SEAL BUSH 213 2 HEXAGONAL HEAD SCREW 600 1 HOLLOW SHAFT o9 ONLY FOR SEALS WITH ANTI ROTATION STATIONARY PART TYPE 120 122 110 Pag 56 02 02 2011 OMI EN PCP 001 ROO Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 2 3 6 Tandem double mechanical seal 9 059 Technical drawings Size Model h7 A B G 4L1 D030 2K2 35 5 5 59 1K4 212 201 210 205 204 200 1011 4 2 0040 2K4 45 5 5 64 16L1 8K2 20L1 10K2 D060 4K4 55 5 5 66 5 30L1 16K2 40L1 20K2 D120 10K4 65 5 5 68 5 60L1 30K2 80L1 40K2 D300 20K4 70 5 5 77 120L1 60K2 SPARE PARTS LIST KEY R RECOMMENDED REPLACEMENT FOR HIGH WEAR PART r RECOMMENDED REPLACEMENT FOR PART NOT SUBJECT TO WEA
5. overall efficiency is the product of the volumetric efficiency and the mechanical efficiency In progressive cavity pumps the axis of rotation of the rotor does not coincide with the axis of rotation of the drive The rotor receives motion from a double jointed drive shaft The function of the rotating unit which includes the drive shaft shaft that connects the drive to the rotor is to transfer the torque given by the drive support the eccentricity of the pumping unit rotor stator bear the axial forces generated by the counterpressure and from the reaction generated by the roto translation between the rotor and the stator 5 3 Structure of the pump Self priming pumps with 1 2 4 stages 8 stages only on specific request The hydraulic part consists of a rotor R and a stator S The pumps can be coupled to the drive in 2 different ways see figure 5 3 1 Directly to the coupling flange M with the transmission directly coupled to the drive A that will be required to withstand the stress provoked by the transmission Type D This pump model features a compact and economical design the motor pump connection is simple and quick to assemble To an independent output shaft with coupling joint for pump and drive Type J This type of pump is less compact and more expensive but allows you to work on the pump without having to disassemble and or move the drive Moreover the support S features high performance bearings ca
6. ssaa detis UE Ue MUI A LI MM 14 7 2 Alignment of the coupling Joint CT ype d rr iri ti Er p d yanasan 14 7 3 th PUMP eases asc ested oie ax 15 7 4 Pipe assembly 215 8 TRANSPORT AND STORAGE u da tete ede tr eeu ERE ede abr usada Lo kaa PURA Rate do Lo da Lu ERA 16 8 1 IPACKING ING TAINS DOM MEME 16 8 2 Eurum M 17 9 START RR RENTA ee ee ae 18 9 1 Preparation Tor Start Up et nt de de e iade pa idea a 18 9 2 PUNE CUOM OR TOVAN OM bu uu M H 18 9 3 IB ecce d Em 19 9 4 S clion pressure Clhack ue riri YE E OY Y ERREUR EL CE Fra EE ete een 19 9 5 19 9 6 19 10 MAINTENANCE 10 1 Wear tear of parts 10 1 1 Rotor and Stator 10 1 2 Joint and Drive Shaft 10 1 3 Seal 10 1 4 Bearing housing MERE 21 10 2 n EE 21 OMI EN PCP 001 02 02 2011 Pag 3 Www castlepumps com AN NOVA ROTORS srl Progressing cavity p
7. the figure 10 6 3 005 t 702 Position the guide bushes 702 as illustrated using the special tool 1 ny 702 10 6 4 705 708 lt Am Mount these parts to the drive shaft in the 7 4 b following sequence elastomer sleeves 705 1 p spiral retaining ring 706 then the joint cover aui 700 Lubricate the sleeve and the drive shaft to facilitate positioning of the parts 06 10 6 5 gt 41 Load ec Align respectively the hollow shaft rotor with the 7 drive shaft so that the guide bush holes ie aligned with the drive shaft holes TUL 9 10 6 6 Insert the pin then use the special tool to position the guide bushes Verify that the pin slides easily that its movement is not blocked Verify the correct mobility of the drive shaft If it does not move 1 L tap the drive shaft gently with a rubber hammer after step 10 6 10 10 6 7 700 FT 4 fel Position the joint cover 708 as illustrated AW opposite the drive shaft 700 and move it back 15 until the sleeve seat and the spiral ring seat are 1 accessible 708 10 6 8 Insert the spiral retaining ring 706 and the sleeve 705 in their respective seats 10 6 9 OMI EN PCP 001 ROO 02 02 2011 Pag 31 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps
8. Pag 32 10 6 10 10 6 11 10 6 13 NO Y NS 10 6 1 02 02 2011 Www castlepumps com Position the joint cover 708 up against the retaining ring taking care not to dislocate the sleeve To facilitate the operation lubricate the contact area with the sleeve and if it is difficult to position tap lightly with a rubber hammer Alternatively place a copper shim between the hammer and the joint cover to prevent damaging the latter Position the retaining ring 709 so that it locks the joint cover Lubricate the joint N B If assembly is carried out with the joint in a horizontal position we recommend pouring in part of the lubricant after steps 10 6 6 and 10 6 8 Apply the clamps 704 using the special tool and ensure that the joint is sealed Make sure that the punching is deep enough to secure the clip Check the tightness of the clamp illustrated If it is too tight it could break the sleeve and affect the functionality of the joint after just a few hours of operation OMI EN PCP 001 R00 AN NOVA ROTORS srl Progressing cavity pumps 10 7 Assembling the seal and close coupled arrangement connections 10 7 1 Procedure for single mechanical seal GOK9 STANDARD 00 9 Position the stationary part of the mechanical seal 203 on the housing 200 Position the housing of the mechanical seal 200 on the coupling flange If it is the housing for a single mechanical s
9. Temperature too low The fluid solidifies Heat the pump Verify suction casing suction head too high or suction head vacuum gauge Increase inlet section or the filter mesh gauge Open the intake valves Air inclusions in process liquid Speed too low with low viscose liquids and intake sections too big Speed too high with very viscous liquids and intake sections too small Risk of cavitation Wrong rotation direction Check the data plate and pump specifications If necessary invert motor polarity Available NPSH inferior to pump demand Cavitation Verify the movement of the drive shaft Incorrect positioning of the transmission bush The pump is running dry either partially or completely Replace the stator if faulty Install a dry run protection probe Stator faulty or worn replace Rotor faulty or worn replace Stator material not suitable Check the order Rotor material not suitable Check the order A part of the transmission is broken Worn out or faulty joint The bearings in the bearing housing or in the drive are no longer suitable Replace them Wrong pump speed Verify and power absorbed at the motor Verify frequency and voltage Viscosity too high Check with pump specifications Gland packing The gland requires adjustment Replace any worn parts Rings and hollow shaft Mechanical seal Check faces and o ring for wear Verify seal
10. 7 I Ig 1 _ ae I J 2 2 22 913 10 8 2 8 M kE 10 8 2 8 38 02 02 2011 www castlepumps com Mount the external crown of the bearing 906 and the spacer 907 Use a pneumatic or hand press for this operation Lubricate the insertion points to facilitate the operation Mount the internal crown of the bearing 906 on the male shaft with the special tool until the bearing rests against the external crown Use a pneumatic or hand press for this operation Lubricate the insertion points to facilitate the operation Mount the lock washer 910 Screw on the ring nut 911 Align one ring nut drain with one washer tooth Tighten the ring nut so that all play is eliminated but do not tighten excessively as this will prevent the shaft from rotating Verify shaft movement manually after the ring nut has been tightened Bend one tooth of the washer 910 on the ring nut 911 as illustrated Position the cover 913 and fix it by tightening the hexagon socket head screws 914 Two lubricators are provided to dispense lubricant Pump the grease through one of the two connections and remove the other one in order to expel the air This will ensure that the housing is completely filled up This will be evident when the grease leaks out from the unobstructed hole Once the housing is filled up plug up the hole either with the lubricator or a plug To replace the lubricant repeat the
11. make sure that the motor is locked out and that it cannot be started accidentally Move the unit slowly and with care particularly on uneven or sloping ground or reckless manoeuvres can lead to the machine overturning with subsequent damage Make sure that the new parking position is safe Avoid locking the front wheels this will increase pump stability while it is running 8 2 Storage The machine must be stored in a safe dry place sheltered from weather conditions If the pump remains inactive for a long period of time rotate the shaft once a month Warning warehousing and incorrect storage can lead to damage Sometimes prolonged storage can lead to problems with various pump parts Stator if inactive for a prolonged period the rotor can permanently warp the stator surfaces This will require a greater starting torque at start up So it is advisable to remove the stator pack it so that it is protected from light and air and store it in a cool dry place Rotor avoid damaging the rotor by protecting it from knocks and blunt instruments Shaft packing seal remove the gland grease the shaft and the bore Stainless steel pump parts do not require protection Other unpainted pump parts grease the parts Drive follow the manufacturer s instructions OMI EN PCP 001 02 02 2011 Pag 17 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 9 START UP PROCEDURES 9 1 Preparation for start up Before star
12. 19 0 2 1 4 1011 4K2 D040 2K4 3 0 5 1 0 2 16L1 8K2 20L1 10K2 0060 4K4 3 0 5 1 0 25 30L1 16K2 4011 20 2 120 10K4 3 0 5 1 0 28 6011 30K2 80L1 40K2 D300 20K4 3 0 5 19 0 32 12011 60K2 As for the dimensions of the independent pump shaft refer to the dimensional drawings provided by Nova Rotors whereas for the drive see the data provided by the manufacturer Pag 14 02 02 2011 OMI EN PCP 001 R00 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 7 3 Mounting the pump No special equipment is required for mounting the pump The pump is mounted by means of its base made of carbon steel or stainless steel depending on the version The entire base must be flat against the foundations The pump must not be installed in sites where the base is larger than the foundation prepared for it It is essential that all the holes provided in the base be used to securely fix the pump The foundation must guarantee correct absorption of the pump weight Refer to the dimensional drawing supplied with the documents attached to each job order for the dimensions of the foundation and the fixing holes Small and medium sized pumps can be moved on a trolley For trailer mounted pumps we recommend releasing the wheel brakes while the pump is running The pump runs in more stable conditions if the brake is not engaged 7 4 Pipe assembly The size and position of the pipes must comply with the specifi
13. 530 0060 4K4 810 30L1 600 JJ 16K2 600 4011 645 20K2 645 D120 1060 60L1 780 30K2 780 80L1 840 40K2 840 D300 20K4 1280 120L1 960 60K2 960 OMI EN PCP 001 ROO 02 02 2011 Pag 15 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 8 TRANSPORT AND STORAGE 8 1 Packing and transport Progressive cavity pumps are packed in specific containers boxes on pallets crates unless the user buyer specifies a different system The packages are marked and useful handling information is applied to them Upon receipt check for damages incurred in transit All damages incurred during transit must be reported immediately to the carrier Use suitable transportation and storage equipment and ensure that appropriate safety measures are observed Depending on the weight the machine can be moved manually or with suitable transport or lifting equipment Bring the packaged pump as close as possible to the installation site and leave it packaged for as long as possible Remove the protection and safety elements used in the packaging and any screws used to secure the packaging to the machine Check and remove any plugs from the suction flange and the delivery flange EJ i VC N Cen a V horizontal axis pump once the packaging has been removed must only be lifted by its The external fixing holes or lifting lugs on the base can be used for this operation
14. Disconnect the pump from the electrical power supply and allow the rotating parts to stop before beginning any operation relating to lubrication The oil volumes that the joints can contain are given below in the table The quantities set out below will guarantee perfect operation and maximum duration of the joints It is not recommended to use less than 70 of the quantity of lubricant specified below Do not use different lubricants within the same joint and prevent it from coming into contact with other lubricants both before and after filling the joint The recommended lubricants are listed in the following table Size oil vol NON FOOD GRADE FOOD GRADE 3 NSF H1 Registered 4L1 D030 2K2 10 184 1011 4K2 D040 2K4 20 cm 16L1 8K2 20L1 10K2 0060 4K4 40 cm 30L1 16K2 4011 20K2 D120 10K4 60 cm 60L1 MaconOil Sint 220 320 MaconOil Sintofluid 220 320 30K2 PAG PAO 80L1 40K2 D300 20K4 100 cm 120L1 60K2 LUBCON TURMOPOLOIL LUBCON TURMOSYNTHOIL 220 320 EP PAG 220 320 PG PAG Pag 20 02 02 2011 OMI EN PCP 001 R00 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 10 1 3 Seal The wear and tear of the seal is related to many factors product abrasiveness pump speed viscosity and the operating temperature The choice of seal system significantly affects its performance Gland packing seal In gland packing seal systems it is the gland packing and the hollo
15. a reconditioned pump or before disassembling the pump for servicing it is advisable to ensure that all process fluid and solid sediment have been cleaned out of the pump operations must be carried out with the pump shut off and disconnected form the electrical power supply 10 1 Wear and tear of parts 10 1 1 Rotor and Stator The wear and tear of these parts is related to many factors the type of process liquid product abrasiveness pump speed pressure and temperature are the major wear factors When pump performance drops to unacceptable values replace one or both parts The process fluid guarantees lubrication of the parts when the pump is running 10 1 2 Joint and Drive Shaft Regular inspection maintenance and lubrication of the joints prolong their life and improve their performance It may be necessary to replace one or both joints sleeve clamps pin bushes joint cover or the drive shaft when they show signs of wear or breakage The use of high quality synthetic oils is fundamental to ensure optimal duration of the joints The lubricants tested by Nova Rotors guarantee performance and compatibility with the elastomers used for the joint protection sleeves Lubricants other than those mentioned below are not entirely guaranteed as they have not been tested and could cause premature wear or breakage of one or more components of the joint We recommend checking and replacing the lubricant in the joint every 8000 hours 6
16. compression Replace worn parts Unsuitable seal system OMI EN PCP 001 ROO 02 02 2011 www castlepumps com Pag 39 AN NOVA ROTORS srl Progressing cavity pumps 2 SPARE PARTS 2 1 Pump parts technical drawings DN L1 K2 K4 SERIES 5 11001 02 02 2011 OMI EN PCP 001 R00 www castlepumps com Pag 40 AN NOVA ROTORS srl Progressing cavity pumps ES 73 E a 55 55 5 EX 2 55 lt 8 35 58 Be 29 lt 00 59 5 xo Sa lt m o ET oF NO 2 D a 95 5 8 gt DICAT 9 8 88 5 s g 2 5 5 a X N WY 9 a 20 us 4 S H j 4 m z a a lt z 5 vol T 20 C 7 lt OMI EN PCP 001 ROO 02 02 2011 Pag 41 www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps SPARE PARTS LIST DN 11 2 SERIES KEY R R ECOMMENDED REPLACEMENT FOR HIGH WEAR PART RECOMMENDED REPLACEMENT FOR PART NOT SUBJECT TO WEAR OR HIGH WEAR POS 100 101 102 200 201 202 203 300 301 302 303 304 305 306 310 311 312 313 320 321 400 401 402 403 404 500 600 601 602 700 7
17. per stage Pumps are available with one to eight stages depending on the required pressure 5 2 Pump operating principle The progressive cavity pump is a volumetric self priming rotary machine The pumping part of the machine consists of two elements the rotor and the stator The rotor normally made of metal is a single start screw with round thread extremely large pitch considerable height and high eccentricity in relation to the core diameter The stator normally made of elastic material vulcanized in a steel pipe is impressed with a cavity in the shape of a 2 start screw double thread compared to the rotor and with the same eccentricity The rotor rotating within the stator is forced to perform a hypocycloid roto translational movement This coupling of the two elements always creates a line of contact along the profile that guarantees the seal between them This movement creates an airtight chamber that shifts with a helical movement from the suction casing to the delivery casing The theoretical flow rate Qt is directly proportional to the number of revolutions It can be calculated using the following equation D 4 2P 60 Qt 10003 Qt theoretical flow rate m h D rotor diameter mm e rotor eccentricity mm P rotor pitch n number of rpm Whereas the absorbed power calculation is P 36 absorbed power KW Q flow rate m3 h H differential pressure Bar
18. shaft connected to the drive by means of a joint Construction Type N Pump body H Hopper The following table groups the models by SIZE that is the mechanical size to which a given group of models belongs Each model belonging to a given size indicates the use of the same transmission without the rotor the same connection to the drive connecting shafts seals and related airtight cases These figures are intended simply as a guide and they are only meant to give a rough indication of the range of uses for the various models For the actual usage data always refer to the order confirmation and to the performance curves provided for each job order Model Qmax 2 bar rpm max P max bar 4L1 11 800 6 D030 2K2 5 9 800 12 1K4 2 1 600 24 10L1 17 3 600 6 4K2 8 7 600 12 D040 2K4 4 15 500 24 16L1 26 600 4 8K2 10 83 600 8 20L1 29 1 500 6 10K2 14 6 500 12 0060 4 4 7 15 400 24 3011 39 5 500 4 16K2 16 500 8 40L1 53 4 500 6 20K2 26 1 500 12 0120 10K4 14 43 400 24 60L1 81 25 500 4 30K2 32 56 500 8 80L1 80 2 350 6 40K2 39 6 350 12 D300 20K4 18 3 300 24 120L1 110 350 4 60K2 47 14 350 8 OMI EN PCP 001 ROO 02 02 2011 Pag 13 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 7 INSTALLATION AND ASSEMBLY 7 1 Positioning of the pump The customer is responsible for evaluating the spaces available in their plant for the installation of the machine When evaluating the space needed for t
19. the hollow shaft 600 there will be the complete rotating unit including the hollow shaft drive shaft rotor and related joint parts This entails greater difficulty in handling the transmission given the additional weights Therefore more care must be taken not to damage the seal parts in case thay are still useable or recoverable This is particularly important if dealing with one or more mechanical seals Otherwise for gland packing solutions this operation can be advantageous as it is unlikely to sustain mechanical damage due to impact 10 4 1 Procedure for single mechanical seal GOK9 STANDARD 00 9 AI An Use a screwdriver to move the splash ring 602 ANN 2 BA until the coupling pin 601 is visible Extract it 0 27 SN from the hollow shaft 600 using an ejector pin Se and hammer Remove the fastening bolts from x the drive or the bearing housing series J and slide out Remove the hollow shaft with the housing 200 still mounted on it and remove the splash ring 602 10 4 1 1 2 500 If the seal has a steel rotating part then the NEZ grub screws must unscrewed 7 Remove ring 202 from the hollow shaft gt 601 it is only present for elastomer bellows seals 10 4 1 2 Remove the mechanical seal housing 200 from the coupling flange Next remove the f stationary part 200 of the mechanical seal 203 from the housing For single mechanical seals with quench re
20. 01 702 703 704 705 706 707 709 800 Qty Description NOTES COUPLING FLANGE CLOSE COUPLED ARRANGEMENT PROTECTION CHEESE HEAD SCREW SEAL HOUSING THREADED PLUG SEAL RING MECHANICAL SEAL STATIONARY PART ROTATING PART B HEX NUT 8 WASHER HEXAGONAL HEAD SCREW O RING THREADED PLUG FOOT PUMP BODY COVER GASKET PUMP BODY COVER 4 WASHER 4 HEXAGONAL HEAD SCREW STATOR ADAPTER RING O RING STATOR TIE ROD HEX NUT WASHER WASHER OUTLET FLANGE HOLLOW SHAFT COUPLING PIN SPLASH RING DRIVE SHAFT PIN GUIDE BUSH TRANSMISSION BUSH CLAMP SLEEVE SPIRAL RETAINING RING O RING JOINT COVER RETAINING RING WIRE ROTOR de ou he zac CEA OO N N N N N N N NN gt O Jo 7 m mmm WEAR OF THE HOLLOW SHAFT DEPENDS ON THE TYPE OF SEAL INSTALLED ON THE PUMP WE RECOMMEND ORDERING THE DRIVE SHAFT 700 AND TRANSMISSION BUSH 703 PREASSEMBLED BY NOVA ROTORS KIT 700 703 FOR TOOLS AND PROCEDURES NECESSARY FOR ASSEMBLY SEE THE SECTION ON JOINT ASSEMBLY DISASSEMBLY ONLY SERIES K4 6 FOR SIZE 300 8011 40K2 20 4 120L1 60K2 ONLY CAST IRON VERSION 4 FOR THE CAST IRON VERSION PARTS BELONGING TO THE SEAL UNIT FOR TYPES OTHER THAN THE SINGLE MECHANICAL SEAL GOK9 SEE SECTION ON SEALS Pag 42 02 02 2011 Www castlepumps com OMI EN PCP 001 ROO
21. 02 201 1 Pag 51 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 2 3 Seal systems technical drawings and spare parts 2 3 1 Gland packing seal 01 technical drawings Size Model rings ring Pack per pack dimensions L 411 210 2 D030 2K2 6 E CE 48 1K4 SUTA 1011 4 2 LE 0040 2K4 6 48 v A 16L1 8 2 601 L 77777 Z 20L1 0060 Ia 6 60 3011 1 218 4 16K2 40L1 20K2 7 D120 10K4 6 se on 60 2 6011 252 rd 30K2 Lb 80L1 md 40K2 2 0300 20 4 6 72 12011 619 60 2 UT END EX NN X Y 1 NM pr N 20 N 20 SPARE PARTS LIST KEY RECOMMENDED REPLACEMENT FOR HIGH WEAR PART RECOMMENDED REPLACEMENT FOR PART NOT SUBJECT TO WEAR OR HIGH WEAR Description 200 1 GLAND HOUSING 203 1 GLAND PACKING PACK R 210 1 GLAND BUSH 211 2 HEX NUT 212 2 STUD 600 1 HOLLOW SHAFT R Pag 52 02 02 2011 OMI EN PCP 001 ROO www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 2 3 2 Gland seal with flushing B02 disegni tecnici Size Model No rings Ring Pack per pack dimensions L 4L1 5 GLAND PACKING RINGS D030 2K2 1 50 1K4 1 FLUSHI
22. 06 on the ring Use lubricant to facilitate the operation If the seal has a steel rotating part then the grub screws of the seals must also be screwed on For the position see section 12 3 5 Mount the second stationary part of the mechanical seal 203 on the double mechanical seal bush 210 10 7 3 3 Mount the double mechanical seal bush 210 and the O ring 205 in their respective seats taking care not to touch the stationary part positioned in the bush 210 with the shaft Tighten the screws 213 10 7 3 4 Pag 34 02 02 2011 OMI EN PCP 001 ROO www castlepumps com 10 7 4 Procedure for tandem double mechanical seal 9 059 10 7 4 1 Na v s 00 rad 10 7 4 1 eU J SR lt lt Xu 200 s 2 10 7 4 1 10 7 4 1 PY Y 203 10 7 4 1 10 7 4 1 OMI EN PCP 001 ROO 02 02 201 1 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps Mount the rotating part of the seal 203 using lubricant to facilitate the operation Tighten the screws on the seal For the position see section 12 3 6 Mount the stationary part of the mechanical seal 203 on the double mechanical seal housing 200 Mount the housing 200 with seal rotating part 203 mounted on the shaft 600 taking care not to touch the stationary part positioned in the housing 200 Mount the rotating part of the second seal 203 using lubricant to facilitate the operation Tigh
23. 1 R00 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 10 3 Disassembly of the joints The procedure for disassembling the joints is set out below to be applied to both the rotor side joint and the hollow shaft side joint The operations can also be carried out after having disassembled the complete transmission as described above In that case we recommend using a suitable clamping tool so the operations can be carried out easily and quickly 9 The operations must be carried out with the transmission locked however do not use devices that interfere with the disassembly operations By identifying suitable fixing positions for each stage you will significantly simplify each separate operation to be carried out on the joint 704 LA Identify the clamp 704 and fastening clip Release the clip without nicking or damaging the elastomer sleeve 10 3 2 retaining ring 709 Pull it away as soon as it slips out of its groove in the opposite direction Use external retaining ring pliers to unscrew the gt to the joint cover and as far back as possible 10 3 3 Move the joint cover 708 in the same direction 08 as the retaining ring facilitate the operation lubricate the contact area with the sleeve and if _ it is difficult to extract tap lightly with a rubber I UT 7 hammer Alternatively place a copper shim between the hammer and the
24. 8 TOOTH LOCK WASHER 902 4 HEXAGONAL HEAD SCREW 903 1 MALE SHAFT R 904 4 HEX NUT 905 1 OIL SEAL R 906 2 TAPER ROLLER BEARING R 907 1 SPACER 908 1 LOCK WASHER 909 1 RING NUT 910 1 OIL SEAL R 911 1 BEARING COVER 912 6 HEXAGON SOCKET HEAD SCREW 913 1 SHAFT KEY 914 2 LUBRICATOR Pag 48 02 02 2011 www castlepumps com OMI EN PCP 001 ROO AN NOVA ROTORS srl Progressing cavity pumps technical drawings JH L1 K2 K4 SERIES pro 5 130011 49 02 02 2011 www castlepumps com OMI EN PCP 001 AN NOVA ROTORS srl Progressing cavity pumps E C Bc M Bc gt x C 20 C CO T gt 20 G2 Z 20 Te gt JE m gt 2 T 50 02 02 2011 OMI EN PCP 001 ROO www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps SPARE PARTS LIST JH L1 SERIES KEY R RECOMMENDED REPLACEMENT FOR HIGH WEAR PART r RECOMMENDED REPLACEMENT FOR PART NOT SUBJECT TO WEAR OR HIGH WEAR POS Qty Description NOTES 900 1 BEARING HOUSING 901 8 TOOTH LOCK WASHER 902 4 HEXAGONAL HEAD SCREW 903 1 MALE SHAFT R 904 4 HEX NUT 905 1 OIL SEAL R 906 2 TAPER ROLLER BEARING R 907 1 SPACER 908 1 LOCK WASHER 909 1 RING NUT 910 1 OIL SEAL R 911 1 BEARING COVER 912 6 HEXAGON SOCKET HEAD SCREW 913 1 SHAFT KEY 914 2 LUBRICATOR OMI EN PCP 001 R00 02
25. AN NOVA ROTORS srl Progressing cavity pumps technical drawings DH L1 K2 K4 SERIES 5 13000 OMI EN PCP 001 02 02 2011 43 www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps Se 2 58 58 voa Su 6 25 42 88 95 55 NO m o gt 28 42 2 x 1 8 5 T 3 2 20 x Co 4 29 09 C 22 lt 44 02 02 2011 001 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps SPARE PARTS LIST DH L1 K2 SERIES KEY R RECOMMENDED REPLACEMENT FOR HIGH WEAR PART r RECOMMENDED REPLACEMENT FOR PART NOT SUBJECT TO WEAR OR HIGH WEAR POS Qty Description NOTES 100 1 COUPLING FLANGE 101 2 CLOSE COUPLED ARRANGEMENT PROTECTION 102 1 CHEESE HEAD SCREW 200 1 SEAL HOUSING 201 1 THREADED PLUG 202 1 SEALRING 203 1 MECHANICAL SEAL STATIONARY PART ROTATING PART p 300 1 PUMP BODY 302 4 WASHER 303 4 HEXAGONAL HEAD SCREW 304 1 R 305 1 THREADED PLUG 320 1 STATOR ADAPTER RING e 321 12 O RING 400 1 STATOR R 401 4 402 8 403 4 WASHER 404 2 WASHER e 500 1 OUTLET FLANGE 600 1 HOLLOW SHAFT rO 601 12 COUPLING PIN 602 1 SPLASH RING 700 1 DRIVE SHAFT 701 2 R 702 4 GUIDE BUSH R 703 2 TRAN
26. ART r RECOMMENDED REPLACEMENT FOR PART NOT SUBJECT TO WEAR OR HIGH WEAR Description 200 1 MECHANICAL SEAL HOUSING 201 1 PLUG 202 1 MECHANICAL SEAL RING 203 1 MECHANICAL SEAL ROTATING PART STATIONARY PART 204 1 PIN 9 600 1 HOLLOW SHAFT R 9 ONLY FOR SEALS WITH ANTI ROTATION STATIONARY PART TYPE 120 122 110 Pag 54 02 02 2011 OMI EN PCP 001 ROO www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 2 3 4 Single mechanical seal with quench 9 technical drawings Size Model h7 A 4L1 D030 2K2 35 8 1K4 10L1 4K2 D040 2K4 45 8 16L1 8 2 2011 10K2 D060 4K4 55 8 3011 16 2 4011 20K2 D120 10K4 65 8 60L1 30K2 80L1 40K2 D300 20K4 70 8 120L1 60K2 SPARE PARTS LIST KEY R RECOMMENDED REPLACEMENT FOR HIGH WEAR PART RECOMMENDED REPLACEMENT FOR PART NOT SUBJECT TO WEAR OR HIGH WEAR POS Qty Description NOTES 200 1 MECHANICAL SEAL HOUSING 201 1 PLUG 202 1 MECHANICAL SEAL RING 203 1 MECHANICAL SEAL ROTATING PART STATIONARY PART R 204 1 PIN 220 1 OIL SEAL R 221 1 RETAINING RING 600 1 HOLLOW SHAFT R 9 ONLY FOR SEALS WITH ANTI ROTATION STATIONARY PART TYPE 120 122 110 OMI EN PCP 001 02 02 2011 Pag 55 www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 2 3 5 Back to back double mechanical seal DOK9 0059 Technical drawings 204 213 210 203 202 205 200 Size
27. NG RING 1011 4K2 5 GLAND PACKING RINGS D040 2K4 121 50 1611 1 FLUSHING RING a e 8K2 20L1 10K2 5 GLAND PACKING RINGS 0060 4 4 Aur 60 30L1 1 FLUSHING RING RUE 16K2 40L1 20K2 5 GLAND PACKING RINGS D120 10 4 27 60 6011 1 FLUSHING RING 30K2 80L1 40K2 5 GLAND PACKING RINGS 0470012 THE FLUSHING RING CAN BE POSITIONED ACCORDING TO 0300 20K4 Lc 275 5 72 APPLICATION REQUIREMENTS 1 FLUSHING RING CUT END X N 20 20 E RAEE LM 5 5 115 R RECOMMENDED REPLACEMENT FOR HIGH WEAR PART RECOMMENDED REPLACEMENT FOR PART NOT SUBJECT TO WEAR OR HIGH WEAR POS Qty Description NOTES 200 1 GLAND HOUSING 202 1 FLUSHING RING 203 1 GLAND PACKING PACK R 210 1 GLAND BUSH 211 2 HEXNUT 212 2 STUD 600 1 HOLLOW SHAFT R OMI EN PCP 001 R00 02 02 2011 Pag 53 Www castlepumps com ANNOVA ROTORS srl Progressing cavity pumps 2 3 3 Single mechanical seal GOK9 technical drawings Size h7 A 4L1 D030 2K2 35 8 184 200 1011 4K2 D040 2K4 45 8 16L1 8 2 601 2011 E 10K2 0060 4K4 55 8 3011 16 2 l 40L1 20K2 D120 10K4 65 8 60L1 30K2 8011 A 40K2 0300 20K4 70 8 120L1 60K2 SPARE PARTS LIST KEY RECOMMENDED REPLACEMENT FOR HIGH WEAR P
28. Progressing cavity pumps AN NOVA ROTORS srl OPERATING USE AND MAINTENANCE INSTRUCTIONS FOR PROGRESSING CAVITY PUMPS SERIES DIAMOND DN JN DH JH CONSTRUCTION TYPE Page 1 02 02 2011 OMI EN PCP 001 WwwW castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 1 INTRODUCTION This manual contains instructions for the correct use and maintenance of the Diamond Series progressing cavity pumps manufactured by NOVA ROTORS S r l The information contained in this manual is intended for the user who is required to read it carefully and to ensure that he has fully understood it before operating the machine The user manual must be available for ready consultation at all times If the manual is lost or damaged contact the manufacturer for a replacement copy qb WARNING The manufacturer is not liable for consequences resulting from an imprudent use of the machine due to the user s failure to read this manual or incomplete reading of it The manual is an integral part of each pump and consequently must be kept throughout the entire service life of the machine and accompany it at all times even if transferred to another user This manual contains instructions required for the safety receiving installation storage correct operation and maintenance of the Diamond Series progressing cavity pumps WARNING NOVA ROTORS S r l reserves the right to modify the specifications referred to in th
29. R OR HIGH WEAR POS Qty Description NOTES 200 1 MECHANICAL SEAL HOUSING 201 q PLUG 203 1 MECHANICAL SEAL ROTATING PART STATIONARY PART 8 204 1 PIN 205 1 O RING R 210 1 MECHANICAL SEAL BUSH 213 2 HEXAGONAL HEAD SCREW 600 1 HOLLOW SHAFT OMI EN PCP 001 R00 02 02 201 1 Pag 57 Www castlepumps com ANNOVA ROTORS srl Progressing cavity pumps AN NOVA ROTORS 180 9001 2008 RWTUV 8 04 ATEX CERTIFICATE 0108 I NovaRot No FM 551921 OHSAS 18001 2007 CERTIFICATE No 2010 915 A 1 Pag 60 02 02 2011 OMI EN PCP 001 R00 www castlepumps com
30. SMISSION BUSH rO 704 2 CLAMP R 705 2 SLEEVE R 706 2 SPIRAL RETAINING RING 707 2 O RING R 708 2 JOINT COVER 709 2 RETAINING RING WIRE R 800 1 ROTOR R WEAR OF THE HOLLOW SHAFT DEPENDS ON THE TYPE OF SEAL INSTALLED ON THE PUMP WE RECOMMEND ORDERING THE DRIVE SHAFT 700 AND TRANSMISSION BUSH 703 PREASSEMBLED BY NOVA ROTORS 700 703 FOR TOOLS AND PROCEDURES NECESSARY FOR ASSEMBLY SEE THE SECTION ON JOINT ASSEMBLY DISASSEMBLY ONLY SERIES K4 PARTS BELONGING TO THE SEAL UNIT FOR TYPES OTHER THAN THE SINGLE MECHANICAL SEAL GOK9 SEE SECTION ON SEALS OMI EN PCP 001 02 02 2011 Pag 45 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 2 2 Spare parts for bearing housing technical drawings JN L1 K2 K4 SERIES 5 30 Pag 46 02 02 2011 OMI EN PCP 001 R00 www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps ev NO ps C 20 CO TI 2 gt 29 27 G2 gt 29 Sy Hart EN val 29 OMI EN PCP 001 02 02 2011 Pag 47 www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps SPARE PARTS LIST JN L1 2 SERIES KEY R RECOMMENDED REPLACEMENT FOR HIGH WEAR PART r RECOMMENDED REPLACEMENT FOR PART NOT SUBJECT TO WEAR OR HIGH WEAR POS Qty Description NOTES 900 1 BEARING HOUSING 901
31. able speed motors The pump can be flanged directly to the coupling flange Type D or with a flexible coupling to an independent output shaft Type J For close coupled pumps Type D the drive is connected to the pump by means of a coupling pin consequently the drives must be suitable for connection to the Nova Rotors D series pumps The drive output shaft must therefore be made according to Nova Rotors specifications The following table indicates the dimensions for the input flange and hollow shaft Size Model input flange 0 05 d F8 h7 411 0030 2K2 160 200 20 8 1 24 35 1K4 10L1 4K2 D040 2K4 160 200 30 12 1 30 45 16L1 8K2 20L1 10K2 0060 4 4 200 250 35 16 1 35 55 3011 16 2 4011 20K2 D120 10 4 250 300 35 18 1 40 65 6011 30K2 8011 40K2 D300 20K4 250 300 38 20 1 50 70 120L1 60K2 input flange 10 02 02 2011 OMI EN PCP 001 R00 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 6 JOB IDENTIFICATION 6 1 Product identification The following information is required to identify the pump for technical data requests for spare parts or orders SERIAL NUMBER SIZE PUMP This information is shown on the data plate affixed to the pump described in the order confirmation 6 2 Technical specifications and documentation Every unit produced by Nova Rotors and eve
32. atmospheres All users must be aware of electricity related hazards and the chemical and physical characteristics of the gas and or steam present in hazardous areas When you start up the machine or carry out maintenance controls or repairs on the machine consider your safety at all times consequently adhere strictly to the general European directives on machinery that have been transposed into national laws to Euronorm EN 12100 2005 to the specific safety standards and the pertinent technical rules Pag 6 02 02 2011 OMI EN PCP 001 R00 Www castlepumps com ANNOVA ROTORS srl Progressing cavity pumps 4 5 Safety quidelines relating to maintenance inspection and assembly work A The user must ensure that all maintenance inspection and assembly operations related to the progressing cavity pumps are carried out by qualified technicians Technicians must carefully read this instruction manual before acting on the pump Only authorised and trained personnel are permitted to work on the progressing cavity pump 4 6 Arbitrary production and transformation of spare parts or modifications to the machine within the limits that do not go beyond extraordinary maintenance are only permitted if agreed on beforehand with the manufacturer Only original spare parts or parts specifically declared as compatible by NOVA ROTORS S r l must be used for regular maintenance operations These parts have been designed specifically for the syst
33. cations in the dimensional drawing provided with the order confirmation Ensure that the diameters of the inlet and outlet pipes are suitable for the required viscosity and flow rate Before connecting the pump thoroughly clean the pipes and remove any built up sediment and or foreign objects The pipes must be connected to the pump in such a way as to prevent any external force from acting on them Fit adequate compensators between the pump and the tubes in order to protect the pump from vibrations that could damage the body Evaluate the reaction forces and the movements of the flexible tubing that will occur when the pump goes into operation Install the inlet and outlet pipes in such a way that when the pump is not working the presence of fluid inside the suction body is guaranteed This will ensure that there is sufficient fluid in the pump to provide lubrication at start up Minimize air inlet to the pump suction casing Ensure enough space to permit easy replacement of the stator Make sure that the pipes can be removed in such a way as to allow enough space to replace the stator The space required for each model is given below In the following table the required distances are given for each model Size Model L 4L1 340 D030 2K2 340 1K4 520 L 10L1 420 4 2 420 660 1611 490 8K2 490 2011 530 10K2
34. e double mechanical seal bush 210 and the O ring 205 from its seat taking care not to touch the stationary part positioned in the bush 210 with the OMI EN PCP 001 R00 10 4 3 3 10 4 3 4 NIA s 210 RS 10 4 3 5 10 4 4 Procedure for tandem doble mechanical seal 9 059 10 4 4 1 OMI EN PCP 001 02 02 2011 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps Loosen the grub screws 206 and extract the rotating parts of the seals 203 and corresponding ring 202 Use lubricant to facilitate the operation If the seal has a steel rotating part then the grub screws must also be unscrewed Extract the hollow shaft from the housing 200 remove the stationary part of the mechanical seal 203 from the housing taking special care not to break it and not to damage the sliding faces in any way Even barely visible damage can affect its functionality Extract the second stationary part of the mechanical seal 203 from the double mechanical seal bush 210 The precautions described in step 10 4 3 4 also apply here Use screwdriver to move the splash ring 602 until the coupling pin 601 is visible Extract it from the hollow shaft 600 using an ejector pin and hammer Remove the fastening bolts from the drive or the bearing housing series J and slide out Remove the hollow shaft with the housing 200 still mounted on it and remove the splash r
35. eal with quench mount the oil seal 220 and the retaining ring 221 on the housing 10 7 1 1 Position the ring 202 followed by the rotating part of the mechanical seal 203 on the hollow shaft 600 use lubricant to facilitate the operation If the seal has a steel rotating part then the screws must be screwed in In this case the ring 2027 is not present and the seal must be positioned as described in the table in section 12 3 3 10 7 1 2 Mount the drive or bearing housing and secure with its hardware Mount the splash ring 602 on the hollow shaft and ensure that the splash ring drain is aligned with the pin Insert the hollow shaft in the output shaft and ensure that the relative holes for the connection with the pin 601 are aligned and apply anti rust protection to the output shaft Lubricate and insert the pin 601 to lock the shafts in position If the pin is difficult to insert tap lightly with a hammer to place it If the ring 602 partially obstructs the hole on the hollow shaft lift it with a screwdriver until the pin 601 is positioned on the shaft itself 10 7 1 3 Q Do not remove the drive or the bearing housing before removing the hollow shaft or the complete transmission as this could irreparably damage the mechanical seal 10 7 2 Procedure per gland packing seal B01 B02 Mount on the hollow shaft 600 the housing 200 all the gland packing seal rings 203 until the entire pack is mount
36. ed on the hollow shaft 600 and the gland packing seal housing 200 If present mount the flushing ring 202 For the position of the flushing ring 202 see section 12 3 2 relative to the gland packing seal with flushing OMI EN PCP 001 02 02 2011 Pag 33 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps Mount the drive or bearing housing and secure with its hardware Mount the splash ring 602 on the hollow shaft and ensure that the splash ring drain is aligned with the pin Insert the hollow shaft on the output shaft and ensure that the relative holes for the connection with the pin 601 are aligned and apply anti rust protection to the outlet shaft Lubricate and insert the pin 601 to lock the shafts in position If the pin is difficult to insert tap lightly with a hammer to place it If the ring 602 partially obstructs the hole on the hollow shaft lift it with a screwdriver until the pin 601 is positioned on the shaft itself 10 7 2 2 10 73 Procedure for back to back double mechanical seal DOK9 0059 Mount the stationary part of the mechanical seal 203 on the housing 203 and the hollow shaft on the housing 200 taking special care not to break the stationary part and not to damage the sliding faces in any way Even barely visible damage can affect its functionality 10 7 3 1 Mount the rotating parts of the seals 203 and relative rings 202 Tighten the screws 2
37. em There is no guarantee that non original parts can withstand the loads and function correctly and safely The use of non original parts voids the warranty immediately 4 7 Noise The A weighted sound power level emitted by the machine does not exceed 854 This value is guaranteed if the pump is installed correctly that is in stable conditions with appropriate fastenings and measured at a distance of 1 metre from the pump It does not include external noise sources or reverberation of the tubes connected to the pump while it is operating Moreover Nova Rotors does not guarantee this value if the machine is used in work conditions that do not comply with those specified in the work order and declared in the order confirmation 4 8 Leakage of hazardous fluids A the pump is used to pump hazardous liquids toxic corrosive etc the volumes of fluid that leak through the seals must be collected and disposed of without endangering human health or the environment 4 9 Protective clothing Wear appropriate protective clothing to protect body parts Safety gloves Wear suitable gloves to protect your hands from various types of possible hazards mechanical electrical chemical and high temperatures Q Clothing and footwear Wear appropriate clothing and safety footwear to protect your feet from falling objects 4 10 Machine maintenance A not disassemble the pump before emptying the tubes Even if the tubes are all empt
38. entifies the pump model and version SERIAL NUMBER Identifies the pump serial number Identifies the pump flow MAX BAR Identifies the pump pressure R P M Identifies the pump speed DATE Identifies the year of manufacture of the pump As well as the data shown on the standard plate this plate includes the Atex mark specific EC mark for protection against explosions and zone classification NOVA ROTORS srl Progressing cavity Pumps 36020 Villaga VI ITALY Tel 39 0444 888151 099 C 39 0444 888152 www novarotors com info novarotors com II 1 2 CEC 07 ATEX 110 MADE IN ITALY POMPA TIPO SIZE PUMP MATRICOLA SERIAL NUMBER DATE R P M LN MAX BAR AN MAX BAR CE1131 identifies the notified body CEC 1131 identifies the group 1 2G identifies the category 2G protection for areas with presence of gas from 10 to 1000 hours year IIB identifies the explosion group T4 identifies the temperature class 4 admissible surface temperature 135 C Pag 12 02 02 2011 001 www castlepumps com ANNOVA ROTORS srl Progressing cavity pumps 6 5 Model identification The DIAMOND series pump code identifies the pump type the construction type and the model Example D H 1011 Pump Type MEM Construction Type Model Pump type D Close coupled Connection flanged directly to the drive J Bearing housing Independent output
39. firmation and on the data plate If you need to use the pump with a direction of rotation different to the direction specified in the order contact Nova Rotors to verify the possibility of changing direction and to define the operating limitations Run the pump motor for a few seconds Make sure that the pumping direction is correct Running the pump in the wrong direction could result in damage to the pump itself The direction of rotation of the pump determines the fluid flow direction The following flow diagrams are based on the direction of rotation Se Pa SONY Counterclockwise rot STD Clockwise rot Pag 18 02 02 2011 OMI EN PCP 001 R00 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 9 3 Delivery pressure check the pump has reached the operating speed check the flow rate and make sure that the pressure does not exceed the value specified on the data plate in the delivery flange Verify the flow rate data and its compliance with the value specified in the order Excessive pipe lengths sediment in the pipes and closed valves can all produce pressure increases that if superior to the pressure declared in the order could lead to destruction of the pump For this reason it is important to monitor the pressure in the pump delivery flange and to adopt suitable overpressure protection systems 9 4 Suction pressure check pressure in the inlet flange must be verif
40. g rests against the shaft Use a pneumatic or hand press to perform this 7 operation Lubricate the insertion points to facilitate the operation 10 8 2 8 X Mount the male shaft on the housing as 24 illustrated The position of the shaft relative to the bearing housing must correspond with the 906 data in the following table Insert the external TN CHE crown of the bearing 906 with the spacer S Ez 907 Use a pneumatic or hand press for this 2 operation Lubricate the insertion points to facilitate the operation gt tnm 2 727 Size Model X 907 A 4L1 D030 2K2 500 0 1 1K4 10L1 10 8 2 9 4K2 D040 2 4 65 0 1 1611 8K2 20L1 10K2 D060 4K4 80 0 1 3011 16 2 4011 20K2 D120 10K4 100 0 1 6011 30K2 80L1 40K2 D300 20K4 100 0 1 12011 60K2 OMI EN PCP 001 ROO 02 02 2011 Pag 37 www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps p 1 B 10 8 2 5 905 PE EA Z N __ D 010 xN SH B 10 8 2 6 10 8 2 7 910 914 2 N 2 pd p
41. gned and built in several variants even its main components including the transmission the pump body C and the outlet flange B depending on the user s requirements All the variations must be defined and verified with Nova Rotors both during the offer stage and the order placement stage 5 3 1 5 4 Pumps with bypass The bypass is a device used to protect the pump against overpressure The bypass consists of an adjustable valve union pipes and flanges which connect the delivery casing with the pump suction casing When the delivery pressure exceeds the preset valve pressure the valve opens and the process fluid returns to the suction casing The setting pressure for single stage models is 6 bar whereas for two stage models it is 10 bar Different settings are possible depending on the processing requirements and they must be consistent with the pump specifications The valve pressure setting must be discussed and agreed on with Nova Rotors The operating limitations must be in accordance with the details specified in the order confirmation and related documents BE lt N
42. he assembly of the joints the seals and the connections to the drive and the bearing housing Select the sequences according to your servicing needs and the type of operation to be carried out Assemble the joints J as described in the procedures set out in Chapter 10 6 both the rotor side and the hollow shaft side N B If the transmission has been completely assembled on the bench it will not be necessary to act on the joints and corresponding components In that case take care not to damage the seal parts when inserting the rotating unit Position the pump body 300 and the O ring 304 Tighten the hexagonal head screws 803 with the hex nut 301 interposing the washers 302 on the support and pump body 300 N B There no hex nuts 301 and washers 302 in the stainless steel version as the screws are screwed directly to the pump body 300 10 5 3 Lubricate the stator 400 with liquid or slightly viscous products soap vaseline silicone spray to facilitate its removal by unscrewing it As soon as possible place a wood block under the rotor to support its weight and to facilitate the extraction of the stator 400 10 5 4 If the stator proves difficult to screw or to handle depends on the pumped product cleanliness and pump size use the special chain 1 1 WS 10 5 5 OMI EN PCP 001 02 02 2011 Pag 29 Www castlepumps com AN NOVA ROTORS srl P
43. he complete management of the pump the following factors must be taken into account The dimensions and weight of the machine in accordance with the dimensional drawing supplied with the order confirmation Machine maintenance Machine handling Speed adjustment if necessary Pressure rpm flow rate readings Adjustment of pressure relief valves if installed Assembly and disassembly of additional protection devices Space required for the use of all the tools necessary for machine operation 7 2 Alignment of the coupling joint Type J For Type J pumps with bearing housing the shaft output is independent and connected to the drive by means of a flexible coupling joint The pumps are aligned and verified at the Nova Rotors factory before shipment If the customer installs his own drive then he will be required to carry out this operation Since transport handling and storage operations could lead to misalignment of the joint it is essential to verify the alignment before starting the machine The table below gives the maximum misalignment values tolerated in the coupling of the joints A is the maximum misalignment value on the longitudinal axis of the two half couplings and B is the maximum permissible angle S is the distance necessary between the two half couplings and the relative tolerance 411 0030 2K2 3 0 5
44. ied and it must never exceed the value specified in the order confirmation as excessive pressure could cause breakage of the seal on the shaft and the shaft itself breakage of the joints or destroy the whole pump For this reason the pressure data for the inlet flange declared in the pump request documents must be guaranteed 9 5 Drives For information on the drives refer to the manufacturer s operating instructions attached to the documents supplied with each job order 9 6 Electrical connections The electrical connection of machines fitted with electrical motors must be made by the user in compliance with the guidelines contained in the standard CEI EN 60204 1 2005 The electrical connections must comply with the manufacturer s specifications and with the safety measures implemented at the installation site Ensure that the mains voltage and frequency correspond to the information on the data plate provided by the manufacturer of the drive Carefully read the motor manufacturer s instructions in the user s guide All the electrical work must be carried out by an authorised operator See the attached specifications and the manual supplied by the manufacturer Particular care should be taken when selecting the section of the conductors when connecting the conductive parts of the pump to the earth circuit to comply with the data on the drive plate with the star delta connection of the drive with the phase connection in order to obtain the r
45. ing 602 Pag 27 ANNOVA ROTORS srl Progressing cavity pumps Loosen the screws 213 extract the double mechanical seal bush 210 and the O ring 205 from its seat taking care not to touch the stationary part positioned in the bush 210 with the shaft 10 4 4 2 Loosen the grub screws and extract the rotating part of the seal 203 Use lubricant to facilitate the operation 10 4 4 3 N 2 j Slide out the hollow shaft 600 together with gx e N the rotating part of the seal 203 taking care NG amp not to touch the stationary part positioned in the m housing 200 with the shaft lt Y 203 10 4 4 4 205 wy Loosen the grub screws and extract the rotating Se E part of the seal 203 Use lubricant to facilitate the operation 10 4 4 5 lt I Extract the stationary part of the mechanical d seal 203 from the bush 210 and from the 2 2 B JJ J housing 200 taking particular care not to v A eA 22 break it or damage the sliding faces in any way W u MCZ M Even barely visible damage can affect its 210 wm 210 e C2 functionality 95 00 203 10 4 4 6 Pag 28 02 02 2011 OMI EN PCP 001 R00 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 10 5 Pump assembly The complete procedure for assembling the pump in sequential order is set out below See the relevant sections for the specific operations relating to t
46. is manual or the characteristics of each machine Some of the illustrations in this manual may include parts that are slightly different to those mounted on your machine 2 EC CONFORMITY Each machine is accompanied by an EC Declaration of Conformity signed by the legal representative of NOVA ROTORS S r l The declaration of conformity states the pump model serial number and order reference The pump has been constructed in compliance with the essential health and safety requirements laid down in the following applicable directives Machinery Directive 2006 42 EC Low Voltage Directive 2006 95 EC Electromagnetic Compatibility Directive The following harmonised standards were also consulted for the design and construction of the pumps UNI EN 809 2009 Pumps and pump units for liquids Common safety requirements UNI EN ISO 12100 1 2005 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology UNI EN ISO 12100 2 2005 Safety of machinery Basic concepts general principles for design Part 2 Technical principles CEI EN 60204 1 2005 Safety of machinery Electrical equipment of Machines Part 1 General rules 9 WARNING This declaration is only valid if the machine is installed used and maintained in compliance with the above mentioned directives and instructions and with the instructions and equipment described in this manual Pag 2 02 02 2011 OMI EN PCP 001 R00 Www castlepu
47. joint cover to prevent damaging the latter 10 3 4 Remove the elastomer sleeve 705 and the spiral retaining ring 706 Use a flat blade screwdriver for both operations 10 3 5 N N Move the elastomer sleeve 705 and the E retaining ring 706 towards the centre of the drive shaft If necessary lubricate the drive shaft to facilitate moving the sleeve 705 10 3 6 OMI EN PCP 001 02 02 2011 Pag 23 Www castlepumps com ANNOVA ROTORS srl Progressing cavity pumps 10 3 7 iml E 10 3 8 10 3 9 101 10 3 10 707 z 111 17 10 3 10 ATM 001 703 ab 2 94 In m ar NN a 002 10 3 11 Pag 24 02 02 2011 Www castlepumps com Push the joint cover 708 previously moved back in the same direction as the sleeve 705 to the same position as the sleeve Pull out the pin 602 N B If the pin is difficult to remove due to seizure or damage use a pin ejector and hammer Bend the drive shaft and using the pin ejector and hammer to eject the guide bush 702 as illustrated bend the shaft the other way and remove the opposing bush If the bushes do not need replacing move them to a position which will allo
48. move the retaining ring 221 and the oil seal 220 from the housing 10 4 1 3 OMI EN PCP 001 02 02 2011 Pag 25 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 10 4 2 Procedure for gland packing seal 01 02 10 4 2 1 10 4 2 1 10 4 3 Procedure for back to back double mechanical seal DOK9 0059 10 4 3 1 10 4 3 2 Pag 26 02 02 2011 Www castlepumps com Use a screwdriver to move the splash ring 602 until the coupling pin 601 is visible Extract it from the hollow shaft 600 using an ejector pin and hammer Remove the fastening bolts from the drive or the bearing housing series J and slide out Remove the hollow shaft with the housing 200 still mounted on it and remove the splash ring 602 Unscrew the hex nuts 211 and remove the gland bush 210 slide out the hollow shaft 600 remove the gland packing 203 from the gland bush housing 200 unscrew the studs 212 For gland packing seals with flushing remove the flushing ring 202 as well as the gland packing 5 Z Use a screwdriver to move the splash ring 602 until the coupling pin 601 is visible Extract it from the hollow shaft 600 using an ejector pin and hammer Remove the fastening bolts from the drive or the bearing housing series J and slide out Remove the hollow shaft with the housing 200 still mounted on it and remove the splash ring 602 Loosen the screws 213 extract th
49. mps com AN NOVA ROTORS srl Progressing cavity pumps Indice 1 INTRODUCTION ERR 2 2 zexeeernp HX 2 3 Ouiebl EB 5 4 6 4 1 Fallure to comply with safety standards reticere tried Hoa Hye da coop ER EAR ELSE EE o HE M Re ERE La A 6 4 2 Stan up Operation ANG iiic rtt i RAM sss sisa asap 6 4 3 Iintended conditions Of o P e Fe ER Fe il 6 4 4 Pumps intended for use in potentially explosive atmospheres 6 4 5 Safety guidelines relating to maintenance inspection and assembly 7 4 6 4 7 4 8 hazardous fluids iioii ia t ca eia aii e re o a resi a n Gee 7 4 9 Protective ET M 7 4 10 Machina maintenance ds 7 5 GENERAL L 8 5 1 Main technical features of progressing cavity 5 8 5 2 Pump operating
50. nd correctly installed on the machine Do not carry out any operation on the safety devices while the pump is operating 4 3 Intended conditions of use Progressing cavity pumps are designed for pumping fluids of the type specified in the order The pump must always observe the operating limitations for which it was constructed and those stated in the order confirmation observe the temperature pressure capacity viscosity and speed limits Unless otherwise stated in the order the pump must not be used in environments subject to the formation of potentially explosive atmospheres 4 4 Pumps intended for use in potentially explosive atmospheres If the pumps are intended for use in potentially explosive atmospheres the fact must be specified in the order and the Atex mark included on the data plate The ATEX directives concern controlling potentially explosive atmospheres and the standards for accessories and protection systems to be used in these atmospheres Atex Directive 2006 42 EC applies specifically to electrical and non electrical accessories The conditions of use must fall within the boundaries that are defined and described in the directive Personnel must comply with the following requirements and rules when working with products have Ex approval in potentially explosive atmospheres All actions on the product must be carried out by licensed electricians or authorised operators Specific rules apply to installations in explosive
51. or even irreparably damage the seal 10 1 4 Bearing housing If the pump is designed with a bearing housing with independent output shaft the lubrication of the bearings inside the housing must be checked regularly We recommend topping up the oil every 4000 work hours We recommend using AGIP GREASE SM 2 We do not guarantee correct operation for other lubricants or if they are mixed with different products with different additives Do not use different lubricants inside the support and make sure it does not come into contact with other types of lubricant s either before or after topping up the support In any case lithium based greases with added molybdenum disulphide can be used For products other than those mentioned contact Nova Rotors Q Disconnect the pump from the electrical power supply and allow the rotating parts to stop before beginning any operation relating to lubrication 10 2 Pump Disassembly The procedures for the complete disassembly of the pump are set out below in sequential order See the relevant sections for the specific operations relating to the disassembly of the joints the seals and the connections to the drive and the bearing housing Select the sequences according to your servicing needs and the type of operation to be carried out Unscrew the hex nuts 402 and remove the washers 403 from the outlet flange 500 to free it Remove the outlet flange 500 10 2 1 Unscrew the hex nuts 401 from the tie
52. otating direction indicated on the pump STAR CONNECTION DELTA CONNECTION N Check the degree of motor protection IP The standard motor protection rating is IP 55 the motor is protected against dust ingress and low pressure water jets Due to the friction between the stator and the rotor greater starting torque may be required at startup Startup could be even more difficult if the pump has been inactive for a long period of time in this case remove the stator and ensure correct lubrication between the stator and the rotor If an inverter is used an incorrect configuration of the parameters could cause problems On motors with inverters having a capacity of 7 5Kw or greater we recommend setting an acceleration ramp of at least 4 seconds whereas for those with lesser capacity a ramp of at least 2 seconds This will ensure less strain at startup Moreover the starting revolutions significantly influence the torques required to start the pump Therefore if any problems arise reduce the machine s startup revolutions OMI EN PCP 001 02 02 2011 Pag 19 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 10 MAINTENANCE All pump maintenance operations must adhere to the instructions set out in this manual Any damage caused by operations that are not compatible with these instructions shall not be deemed the responsibility of or chargeable to Nova Rotors During the installation of a new pump
53. ousing ERES with the entire bearing block mounted on it Use a pneumatic or hand press to perform this operation 25222770 10 8 1 3 906 906 006 N Remove the bearings 906 except for the internal crown of the bearing resting against the male shaft and the spacer 907 from the male shaft with the special tool 7 Use a pneumatic or hand press to perform this lt operation 907 10 8 1 4 lt gZ Remove the internal crown of the bearing remaining on the shaft with the special tool 007 10 8 1 5 36 02 02 2011 OMI EN PCP 001 www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 2 Remove oil seals 910 905 from the cover and the housing 4 uc X 910 905 5 10 8 1 6 10 8 2 Assembly of the bearing housing 008 NT abt Mount the oil seal 910 with the special tool to the housing cover and the seal 905 on the EI bearing housing with the special tool Lubricate the insertion points to facilitate the ATM 009 operation 905 10 8 2 7 Mount the internal crown of the bearing 905 on the male shaft with the special tool until the gt bearin
54. pable of withstanding all the stress provoked by the transmission Type J is more reliable and robust than Type M The bearings require correct lubrication to be able to work efficiently The connections can be of various shapes and sizes either flanged or quick connectors clamps threaded or special Construction type N Additional attachments can also be included in order to have 2 or more suction flange additional attachments to allow CIP The pump body C can be built with a feed hopper with custom dimensions Construction type H For each construction type the bodies have dimensions optimised for the passage of high viscosity fluids and fluids containing solids Pag 8 02 02 2011 OMI EN PCP 001 R00 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps There are 2 joints J inside the pump body C that permit the transmission of torque in the presence of eccentricity The shape and size of the joints are the result of maximum operational reliability sturdiness and of an optimal fluid passage They are sealed with a rubber protection element and their internal parts require perfect lubrication The standard shaft seal T is a single mechanical seal but the machine can be configured with gland packing seals or back to back double mechanical seals On request cartridge seals or other seals can be used Both with mechanical and gland packing seals suitable seats are available for the seal flushing The pump can be desi
55. principle 224 1 t 8 5 3 Structure Of th pUMD m 8 5 4 With 9 5 5 CHECK VAIVES uuu 10 5 6 Dry t n protection ss 10 5 7 6 JOB IDENTIFICATION 6 1 Product identification HER 11 6 2 Technical specifications 11 6 3 Standard Data Plate 1 n i si aod a c e i Ea B v a a P B XR RE REA EE REDE AR ini eee 12 6 4 Atx Data 12 6 5 Model identificati m 13 7 INSTALLATION AND ASSEMBLY cvs 62 14 7 1 Positioning
56. procedure the used oil will be replaced by the new oil The used old grease will be evacuated through the open hole OMI EN PCP 001 R00 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 TROUBLESHOOTING TABLE PROBLEM z z 6 2 a 5 u 5 5 2 5 555 8 e tc 5 9 gt g lt lt lt m 5 Z 5 2 198 0 1 2 E 55 51214105 8 5 5 9 088 5 lt gt n 2 2 gt o lt lt T 2 iL 2 9 L a hr 2 3 L 2 im e E AN NOVA ROTORS srl Progressing cavity pumps PROBABLE CAUSES SOLUTIONS Adhesion between rotor and stator even if new or in perfect condition due to prolonged inactivity Lubricate and move the stator with the special tool Excessive pressure on pump outlet port Foreign body inside the pump Disassemble the pump eliminate the object and place any damaged parts Verify the fluid temperature Expansion of the stator is too high and blocks the rotor Stator is inflated or burned out Dimension of the solids in the fluid are too big Reduce the rpm or install a filter at the pump suction casing The product tends to sediment and or crystallise when the pump is inactive Flush the pump disassemble and clean if necessary Air leakage at suction casing or from the seal
57. ranty and lead to the loss of any compensation for damages Keep these instructions and all related documents together ensure that they are legible and easily accessible to all employees Do not remove any safety equipment before operating the system or during its operation Make sure that there is no evident danger before powering up the system The system must be inspected regularly to check for damage and to ensure that all safety devices are in good working order The pump contains moving parts Do not insert limbs or materials other than the processing material while the pump is functioning In the event of malfunction danger or lack of appropriate safety systems shut down the pump immediately and inform the qualified personnel 4 2 Start up operation and maintenance The plant designated to receive the progressing cavity pump is non an integral part of the supply consequently the customer is required to verify the suitability of the machine for his specific needs to provide the necessary processing data for a correct selection of the pump type and the accessories needed to guarantee the safety of the plant If the user notices that any accessories he considers useful or essential are missing in the order confirmation it is the customer s responsibility to contact the manufacturer and request that the accessory or accessories be applied to the machine While the pump is being used the safety devices provided must be present a
58. rods 401 to release them for removal Unscrew the tie rods 401 from the body 10 2 2 OMI EN PCP 001 ROO 02 02 2011 Pag 21 www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps Lubricate the stator 400 with liquid or slightly viscous products soap silicone spray to facilitate its removal by unscrewing it As soon as possible place a wood block under the rotor to support its weight and to facilitate extraction of the stator 400 10 2 3 If the pump is stuck to the rotor or proves to be difficult to move depends on the pumped liquid cleanliness and pump size use the special chain 10 2 4 Unscrew the hexagonal head screws 303 from the hex nut 301 remove the washers 302 from the support and pump body 300 slide out the pump body 300 and the O ring 304 N B There are no hex nuts 301 and washers 302 in the stainless steel version as the screws are screwed directly to the pump body 300 10 2 5 Disassemble the joints J as described in Chapter 10 3 both on the rotor side and the hollow shaft side N B If you only need to work on the seal you can avoid disassembling the joints and simply follow the procedure for disassembling the connections of the close coupled arrangement and the seal itself directly as described in section 10 4 In that case take care not to damage parts of the seal that are still useable 10 2 6 Pag 22 02 02 2011 OMI EN PCP 00
59. rogressing cavity pumps Screw the hex nuts 402 to the tie rods 401 Screw the tie rods 401 to the body screw the hex nuts 401 into the body in such a way as prevent the tie rods from rotating 10 5 6 Position the outlet flange 500 on the stator Insert the washers 403 on the tie rods and screw the hex nuts 402 until the outlet flange abuts the stator 10 5 7 10 6 Joint assembly amo Position the drive shaft 700 a pneumatic or 703 hand press capable of splining extracting the guide bushes 703 from the lodging and place it on the special table p D L D Insert the special tool in the bush and proceed AIM 002 x 2 with the splining SSS N B The extractor drift must be centred with the guide bush on which the special tool is inserted gt 7 hiec il 28 CORRECT INCORRECT 10 6 1 707 4 Mount the O ring 707 both on the hollow shaft M and the rotor Take care not to damage the in any way as this could affect its sealing efficiency 10 6 2 Pag 30 02 02 2011 OMI EN PCP 001 ROO Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps IM Mount the retaining ring 709 set back from its seat as illustrated
60. ry unit relating to a job order is accompanied by specific documentation These operating instructions are an integral part of the pump However for a correct use of the machine it is essential to refer to other documents as well Every pump we produce is supplied with technical documents which must be accessible at all times to personnel charged with managing the pump Specific documentation relevant to special pumps or custom pumps must be requested before the order is finalised Every job order is supplied with documents certified by Nova Rotors solely for the machine specified in that job order The following table indicates the documents that accompany every job order and the purpose of each technical annex Document Purpose Technical specification operating conditions operating limitations Continmation product configuration Operating and Maintenance Use and maintenance conditions of the unit Pump drawings with Instructions numbered parts Parts and spare parts lists Dimensional configuration operating dimensions connection Dimensional Drawing dimensions ON REQUEST Performance Curve Performance Data Performance data of the pumping unit Performance Test Performance and functional testing of the specific unit ON REQUEST Documents for Third Party Technical documentation use and maintenance documents Parts relating to the third party parts supplied with the unit Declara
61. t up the pump must be filled with liquid This initial procedure is not needed for priming purposes but serves to provide the necessary lubrication for the stator until the pump primes the process fluid Dry running increases friction between the rotor and the stator thereby generating unacceptable high temperatures This heat develops rapidly and completely ruins the contact surfaces between the rotor and the stator When the pump stops due to long breaks in the process fluid delivery or due to plant shut down it is essential to clean the pump that is remove all solids sediment corrosive fluids or fluids that tend to crystallise and in general all residual fluids inside the pump Avoid formation of ice inside the pump If the pump is inactive for brief periods due to the stages in the process cycle the residual liquid inside the pump will be sufficient to prevent a dry start If a clean empty pump is moved or if it is disassembled and reassembled it must be filled up again DO NOT DRY RUN THE PUMP 9 2 Direction of rotation Check the direction of rotation see the plate affixed to the pump The possible directions of rotation are indicated in the pump dimensional drawing To verify the operating limitations relating to the direction of rotation adhere to the specifications in the order con
62. ten the screws on the seal For the position See section 12 3 6 Mount the second stationary part of the mechanical seal 203 on the double mechanical seal bush 210 Mount the double mechanical seal bush 210 and the O ring 205 in their respective seats taking care not to touch the stationary part positioned in the bush 210 with the shaft Tighten the screws 213 Pag 35 AN NOVA ROTORS srl Progressing cavity pumps 10 8 Bearing housing module Type J The addition of this module transforms the closed coupled pump into a pump with bearing housing The end coupling of the drive and male shaft is made with flexible couplings with protection guard 10 8 1 Disassembly of the bearing housing 910 o 914 gt 225 Z N ndo the hexagon socket head screws 914 and remove the cover 913 Bend the teeth of the lock washer 910 8 outwards to disengage it H E 4 1 915 4 10 8 1 1 gt 2 M 911 910 u N po EZ XZ NM Unscrew the ring nut 911 and remove the lock KS 910 IST IZ 12 2 2 4 4 10 8 1 2 Qni d a 2777 N B Extract the male shaft 903 from the h
63. tion of Conformity Conformity with the machinery directive Supplementary ATEX Operating instructions for potentially explosive environments Instructions ONLY ATEX PUMPS OMI EN PCP 001 02 02 2011 Pag 11 www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 6 3 Standard Data Plate The data plate affixed to every progressing cavity pump carries the CE symbol and the following information Manufacturer NOVA ROTORS S r l Address via Villa 29 Town 36020 Villaga VI SIZE PUMP Identifies the pump model and version SERIAL NUMBER Identifies the pump serial number Identifies the pump flow rate MAX BAR Identifies the pump pressure R P M Identifies the pump speed DATE Identifies the year of manufacture of the pump The arrow on the bottom of the plate indicates the pump rotating direction NOVA ROTORS srl Progressing cavity Pumps 36020 Villaga VI ITALY Tel 39 0444 099 MADE IN Fax 39 0444 888152 www novarotors com info novarotors com POMPA TIPO SIZE PUMP MATRICOLA SERIAL NUMBER DATE m h R P M MAX BAR MAX BAR 6 4 Atex Data Plate An Atex approved data plate is required for pumps intended for use in a potentially explosive atmosphere The data plate affixed to every progressing cavity pump carries the CE symbol and the following information Manufacturer NOVA ROTORS S r l Address via Villa 29 Town 36020 Villaga SIZE PUMP Id
64. umps 10 3 Disassembly of the Joints eli E Dei E nilo eat 23 10 4 Disassembly of connections to the close coupled arrangement and seals sse 25 10 4 1 Procedure for single mechanical seal GOK9 STANDARD 0 9 25 10 4 2 Procedure for gland packing seal B01 7 B02 l u icio cii entenderse tete eit ertet dodi tette e Ie ee Roe dada 26 10 4 3 Procedure for back to back double mechanical seal DOK9 059 26 10 4 4 Procedure for tandem doble mechanical seal KOK9 K0S9 10 5 Pump assermb susu haapa 10 6 E M 30 10 7 Assembling the seal and close coupled arrangement 33 10 7 1 Procedure for single mechanical seal GOK9 STANDARD 0 9 33 10 7 2 Procedure per gland packing seal BOT 02 200 33 10 7 3 Procedure for back to back double mechanical seal DOK9 0059 34 10 7 4 Procedure for tandem double mechanical seal KOK9 059 35 10 8 Bearing housing module Type J u uu tto tti itii tust decia He ipe Ha s
65. ven d ao 36 10 8 1 Disassembly of the bearing 36 10 8 2 Assembly of the bearing housirig tertie idi teet E E e ere E PEE EHE ka EE pute 37 TROUBLESHOOTING TABLE 39 SPARE PARTS C 40 2 1 PUMP u s si u uuu 2 M 40 2 2 Spare parts fok bearing 46 2 3 Seal systems technical drawings and spare parts nnns 52 23 Gland packing seal ict ened eee eee aes nes eee ee E eee ee 52 2 3 2 Gland s al with flushing 02 53 2 3 3 9 lt ce 54 2 3 4 mechanical seal with Quench QOKQ 55 2 3 5 Back to back double mechanical seal DOK9 00899
66. w shaft that wear down and to a lesser extent the airtight case as well The gland packing is economical and easy to maintain It is important to adjust the gland regularly in order to guarantee a limited leakage of the process fluid between the hollow shaft and the gland packing This leakage is necessary for a correct lubrication of the gland packing To begin with 50 200 drops per minute are allowable After 30 minutes adjust the gland bush until the rate reaches 5 20 drops per minute If the temperature of the gland packing exceeds the process fluid temperature by 20 60 loosen the gland bush and repeat the adjustment procedure as indicated above Flushing rings can be fitted with different positions according to the process conditions in order to lubricate the gland packing with non process fluid In addition one or more rings can be replaced with lip seals for applications that require them Mechanical seal In mechanical seal systems the seal itself is the only element that wears down rotating part and fixed part Consequently the hollow shaft does not contribute to wearing the system The mechanical seal limits the leakage losses more than the gland packing system as the quantity of fluid necessary for the lubrication of the sealing faces is very low Typical leakage ranges between 0 5 1 ml h Mechanical seals can be single back to back double tandem double single flushed or with quench Dry running even for just a few seconds can ruin
67. w you to remove the drive shaft Slide out the drive shaft 700 from the joint casing Next remove the sleeve if it requires replacing Remove the O Ring 707 from the joint casing Position the drive shaft 700 in a pneumatic or hand press capable of splining extracting the guide bushes 703 from the lodging and place it on the special table Insert the special tool in the bush and extract it N B The extractor drift must be centred with the guide bush on which the special tool is inserted OMI EN PCP 001 R00 AN NOVA ROTORS srl Progressing cavity pumps 10 4 Disassembly of connections to the close coupled arrangement and seals The procedures for disassembling the seals and the connections with the drive or bearing housing are set out below The procedures vary according to the type of seal selected The choice of seal depends on the processing work required of the pump Consequently it is important to identify the type of seal that has been fitted and defined according to the technical specifications of the particular machine and carry out the corresponding operations in the sequence described below The machine must be shut off and made safe before any tests or controls are carried out on the seals If you need to check for leaks from seal do not remove protections or safety devices As mentioned previously the operations can be carried out without removing the entire transmission In that case instead of
68. y some liquid could remain in the pump The fluid can be hazardous to human health and the environment can be very hot maintenance work must be carried out with the machine shut off from the power supply AN beginning maintenance on the pump remember to disconnect the power supply by means of the circuit breakers All the devices must be secured against automatic or accidental restart Where possible turn the main switch to OFF and remove the key In particular situations where you need to run the pump while servicing at least 2 persons must be present so that in the event of danger one person will be able to disconnect the power supply or raise the alarm Once maintenance has been completed remember to restore the safety devices and check that they are in good working order OMI EN PCP 001 02 02 2011 Pag 7 Www castlepumps com AN NOVA ROTORS srl Progressing cavity pumps 5 GENERAL 5 1 Main technical features of progressing cavity pumps Uniform flow and proportional to the number of revolutions Self priming with a minimum suction capacity of 4 mWC NPSH depending on the size the number of stages and pump speed Capacity to pump heterogeneous products containing gases and abrasives or solid and fibrous materials in the liquid matrix Pumping of liquids with low or high viscosity Dosing of liquids Pulse free pumping with minimum tensile strain of the product being processed High pumping pressure 6 bar

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