SSP M/103/0301 User's Manual
Contents
1. B B L m a Ta 2 n ms A Port J O wS Size E g A 4 L 1 o x Ao oss 2 e LL O 0 y Q O o o EL ry jp J OF at 1 c O O o o JR HB CRI 0 04 ra m L E ES E R ml 4 S Holes U M P N gt a gt All dimensions in mm PUMP A B C HT J L M T MODEL D4 0095 75 170 163 307 20 38 80 115211 63 41 10 597 122 225 150 35 255 184 150 14 338 D4 0140 100 170 163 307 20 38 80 115211 63 41 10 628 138 225 150 35 255 184 150 14 338 315 D5 0290 195 371 20 45 110 13525570 315 D5 0290 195 1371 20 45110 135 255 70 48 5 14 747 145 279 180 35 2751210 180 14 D6 0420 150 225 225 429 20 48110 155 295 70 51 5 14 832 163 266 260 40 370 220 190 14 D6 0600 150 225 225 429 20 48 110 155 295 70 51 5 14 857 188 266 260 40 370 220 190 14 Dimensions when priming adaptors are fitted 5 14 719 145 279 180 35 275 210 180 14 D5 0200 195 371 20 45 110 135 255 70 M48 5 14 699 125 279 180 35 275 210 180 14 48 The above dimensions are for guidance only and should not be used for installation purposes Certified dimensions are available upon request Operating Manual 3 4 Pump and Pump Unit Weights Jm Bareshaft2. of a turn until the leak is at an acceptable rate Important Stop and remove gland guard for checking temperature of housing and observing leakage Always replace the guard before re starting 1 Lightly tighten up the gland follower 2 Flood the pumphead and determine if the gland leakage is acceptable Tighten the gland follower nuts until an acceptable leakage is achieved 3 Start the pump and allow to run for 10 minutes Ifthe gland becomes significantly hotter than other parts of the pump the gland is too tight 41 11 6 Mechanical Sewage Seal Item Description Bronze Bush Gasket Socket Set Screw Wave Spring O Ring Shaft Seal Housing Shaft Rotorcase Rotary Assembly Rotary Face Stationary Face O Ring Housing 1 2 3 4 5 6 T 8 9 The Sewage Seal comprises of an internally mounted single mechanical seal bronze bush and seal housing The single mechanical seal has a rotary face which is sealed to the shaft by an O ring A wave spring provides a force to maintain face to face contact Rotation is provided by socket set screws which are tightened onto the shaft The stationary face is located in the seal housing and is prevented from rotating by three pins Seal setting is provided by the bronze bush which locates in the rotorcase with three pins Mechanical seal faces are brittle Take exteme care when handling Disassembly 1 Remove the seal housing plug and loosen
3. 5 Ensurethatany additional equipmentsuch as sealflushing pipework is not damaged Pump Pedestal Mounted 2 3 Handling Refer to the pump weights guide prior to using any lifting gear Use the correct lifting slings for the pump weight or pump and drive if applicable The following details show how the pumps should be lifted Bareshaft Pump the slings should be wrapped around the ports and the drive shaft Pump with in line Drive Unit the slings should be positioned around the pump rotorcase and under the motor Note To stop the slings slipping always cross the slings on the lifting hooks Bareshaft Pump Pump with in line Drive Unit 2 4 Pump Storage After receipt and inspection if the pump is notto be installed immediately the pump should be repacked and placed in suitable storage The following points should be noted ik Plastic or gasket type port covers should be left in place Pumps received wrapped with corrosion inhibiting treatment material should be rewrapped Aclean dry vibration free location should be selected If stored in a moist atmosphere further protect the pump or unit with a moisture repellent cover until it is to be installed Operating Manual Rotate pump pump unit by hand we
4. Toretime the rotors only one ofthe timing gear retainers need to be released sufficiently to allow the rotors to be tapped into a position where they are synchronised The rotors are correctly synchronised when the clearances at the measurement points are equal Diagram of Rotors Showing Timing Use feeler gauges to measure the clearances at the positions illustrated and adjust until equal the pumpis then correctly timed Tighten the screws of the torque locking assembly to the correct values and replace the gearcase cover 10 3 Timing Adjustment Removing the timing gears is a reasonably simple operation though difficulty may be experienced in sliding the gears off the shaft If this is the case an extractor tool may be required For this purpose threaded holes are provided in the gears Measuement Operating Manual To remove the timing gears the following procedure is recommended 1 Drain lubricant 2 Remove rear gearcase cover 3 Release torque locking assemblies refer to page 23 8 2 4 An extractor tool may be required to pull the gear off Because the gearcase has twin lubricated chambers lubricant may drain out when the top gear is removed 10 4 Lip Seal Removal amp Refitting The bearing lip seal fits behind the top shaft rear bearing housing The lip seal runs on a boss at the back of the timing gears and prevents the top chamber lubricantfrom draining into the bottom chamber If the lip sea
5. Take extreme care when handling Removing the Single Mechanical Seal 1 Torelease the seal from the shaft loosen the socket set screws 2 Remove the rotorcase with the stationary sealing face still within its bore taking care not the chip the face 3 Carefully remove the remaining part of the seal from the shaft 37 Fitting the Single Mechanical Seal 1 Use a solvent to wipe the lapped surface of the seal faces until perfectly clean being extremely careful not to scratch the faces Lightly lubricate the O ring and shaft end with a silicon grease food quality if necessary Firmly press the stationary face O ring onto the stationary face edge and locate within the rotorcase bore over the roll pins Mark the shaft to indicate the seal setting length Push the O ring within seal assembly face bore and gently slide the seal onto the shaft until it reaches the setting position Tighten the socket set screws Abutment Spacer 11 2 Single Mechanical Seal ee meemem Stationary Face O Ring Stationary Face Rotary Face Shaft O Ring Wave Spring Drive Ring Spacer O Ring Spacer Gasket Seal Housing Lip Seal OANDOABRWDND The seal comprises of a rotary face which is sealed to the shaft by an O ring A wave spring s provide a force to maintain face to face contact Rotation is provided by socket set screws which are tightened onto the shaft The stationary face is
6. 89 392 EEC as amended by 91 368 EEC 93 44 EEC and 93 68 EEC and to the following other relevant directives The machinery has been designed and manufactured in accordance with the transposed harmonised European standards European and national standards as listed Machine Description Rotary Lobe Pump Motorised Type Size Serial Number Other Applicable Directives Electrical Equipment Low Voltage Directive 73 23 EEC Electromagnetic Compatibility Directive 89 336 EEC Applicable Standards Specifications EN292 Parts 1 and 2 1991 Safety of Machinery Basic concepts general principles for design EN294 1992 Safety distances to prevent danger zones being reached by the upper limbs EN60204 Part 1 1993 Safety of Machinery Electrical equipment of machines specification for general requirements BS5304 1988 Code of Practice for Safety of Machinery ISO9001 2000 Quality Management System A technical construction file for this machinery is retained at the above address Signed VASA O Date Authorised Person Name P SWEET Position QUALITY MANAGER CC Contents General Pump Limits of Application or Use Duty Conditions Noise Levels Utility Requirements Safety Precautions Health and Safety Information Unpacking Handling and Storage Documents Unpacking Handling Pump Storage Description of Pump or Pump Unit General Pump Description Principle of Operation Pump Dimensions Pump and Pump Unit Weigh
7. is sealed with three O rings per rotor A B amp C one A between the shaft and rotor and two B amp C seated in the rotor cap The rotor caps are retained by socket head cap screws The TLA s should be tightened to the recommended torque values O Ring C O Ring B e O Ring A Note O ring A is fitted in a recess on pumps D5 and D6 8 1 TLA Mounting Instructions When fitting a TLA it is recommended that 1 TheTLAis lightly oiled on all surfaces to assistin achieving the correcttorque value and to aid its release when removing 2 Once fitted into its working position and before tightening a temporary rotor clamp supplied with the pump should be used to ensure the rotor with TLA is positively abutted against the shaft shoulder This will ensure that rotor clearance on both its front and rear are maintained Operating Manual 3 Using the rotor clamp with the rotor correctly positioned on the shaft and the TLA in place a suitable screw is put through the centre hole in the clamp and tightened into the end of the shaft This will hold the rotor in place and the TLA screws may now be tightened through the access slots in the clamp 4 With the rotor clamp secured in place the TLA screws can be torqued up to the correct settings To obtain best results it is recommended the screws are tightened in a diametrically opposed pattern repeating until correctly set 8 2 TLA Releas
8. itmay require a sharptap with a malletand punch to break the joint With the cover removed press out the oil sealfromthe coverand replace with a new seal Clean the faces of both the gearcase and the end cover coatthe faces with a suitable liquid gasket and refit the end cover Replace the retaining screws then centralise the lipseal on the shaft before tightening to the recommended torque value Refill the pump with oil 9 8 Refitting the Rotorcases 1 31 All rotors in the series D pump range have sealing O rings as described previously Check the condition of the O rings and fit new rings if necessary Rotors are fully interchangeable When refitting the rotors correcttiming is achieved by replacing the rotors in exactly the same positions as when removed If the gears have been removed or the gearbox dismantled the pump will have to be retimed as described in the timing adjustment section To refit the rotors the recommended procedure is as follows centreline of shaft rotate the drive shaft until the keyway s uppermost not essential find the master lobe of the rotor which centre line is the same as that of the spline teeth See below 1 centreline of lobe spline tooth line the master lobe up with the shaft spline and slide the rotor onto the shaft find the master lobe of the remaining rotor as previously done slide the rotor on so that both rotors are in the position show
9. located in the rotorcase and is prevented from rotating by three pins A seal housing with lip seal encloses the seal and runs on a shaft sleeve Seal faces are brittle Take exteme care when handling Removing the Single Flushed Mechanical Seal 1 To release the seal from the shaft loosen the socket set screws through the flushing connection 2 Remove the seal housing retaining nuts and pull it away from the rotorcase 3 Removethe rotorcase with the stationary sealing face still within its bore taking care not to chip the face 4 Carefully remove the remaining part of the seal from the shaft followed by the seal housing lip seal and spacer Operating Manual Fitting the Single Flushed Mechanical Seal 1 Press the lip seal into the seal housing 2 Lubricate spacer O ring fit into spacer and push onto the shaft 3 Carefully guide the seal housing with lip seal over the spacer 4 Usea solvent to wipe the lapped surface of the faces until perfectly clean being extremely careful not to scratch the faces 5 Lightly lubricate the O ring and shaft end with a silicon grease food quality if necessary 6 Firmly press the stationary face O ring onto the stationary face and locate them within the rotorcase bore over the roll pins 7 Push O ring within seal face bore and gently slide the seal onto the shaft until it reaches the spacer 8 Tightenthe socket set screws through the flushing
10. power and control supplies purge the system if any noxious products have been pumped Read the safety section carefully Ensure isolating valves to the pump are closed Carefully loosen the front cover retaining screws there may still be residual pressure inthe system Remove the front cover retaining screws and take off the cover D5 and D6 pumps may have hinges fitted to the front covers Having removed the front cover retaining screws the cover can be swung to one side Flush out the pumphead with a suitable cleaning agent before continuing Remove the rotor cap and torque locking assemblies Before removing the rotors their position should be noted such that they can be replaced easily Mark the master rotor lobe which centre line corresponds with the rotor spline teeth See below master lobe spline teeth Extract the rotors which should slide out from the splines An internal groove is provided in the front of the rotor into which a suitable tool may be inserted to aid extraction An illustration of a typical tool is shown below Typical rotor extraction tool 9 3 Removing the Rotorcase 1 Before proceeding disconnect the suction and discharge piping Remove the rotors as described previously On pumps D5 and D6 shutthe hinged front cover where fitted and loosely fasten with front cover screws Loosen gland followers or when fitted with a flushed seal arrangement remove the housing ret
11. the middle ring of packing The shaft sleeve equivalent should be used to secure grub is retained to the shaft by three socket set screws in their positions screws and is sealed by an O ring 3 Fitglandspacer gasket and gland housing Removing the Packed Gland to the rotorcase 1 Release and pull back the gland follower 4 Insertthe packing rings and lantern ring if flushed packed gland Make sure they 2 Remove the rotorcase with gland are in the correct order and positioned housing packing and gland follower still with the scarf joints 120 apart assembled 5 Loosely locate the gland follower and 3 Loosen the shaft sleeve socket set nuts screws and extract the sleeve from the shaft 6 Refit the rotorcase with packed assembly over the shaft sleeves 4 Inspect and replace the packing and shaft sleeve if necessary 7 Adjust the packed gland see next page 40 Operating Manual 11 5 Packed Gland Adjustment Packed Gland with Flush nh CENE EU ND Shaft Sleeve O Ring Gasket Shaft Sleeve Gland Housing Spacer Gland Follower Packing Rings Ring Slinger Lantern Ring 4 Stop the pump and allow it to cool then repeat the above until the gland temperature is stable and gland slightly weeping Adjusting the Packed Gland Drip leakage is essential to prevent overheating of the gland area which will cause seal failure 5 Run the pump at 10 minute intervals tightening the gland follower nuts by a
12. to isolate the pump when necessary Pipework Support 15 Keep Check Install Pipework Support Pipework horizontal where applicable to reduce air locks Include eccentric reducers on suction lines Coupling alignment during installation to highlight pipework alignment support problems A liquid trap around to pump to assist in priming See below Non return valve Fluidtrappedto maintain prime 5 0 Commissioning 5 1 Recommended Lubricants Pumps specified oil filled The pump will not be supplied with oil therefore the table below must be used to select a recommended oil Cil Filled 20 C to 130 C BP Energol GR XP150 Castrol Alpha SP150 Mobil Gear 629 Shell Omala 150 Texaco Meropa 150 Esso Spartan EP150 Operating Manual 5 2 Lubricating the Pump Changing the Oil First change After 150 hours of operation Next change Every 3000 hours of operation Only use the oil types recommended by your supplier Fill with oil through the filler plug to the level indicated in the sight glass Cil Filling Bottom Chamber Litres Chamber Litres Note Ensure all ancillary drive units are lubricated according to the manufacturers instructions 16 Operating Manual 5 3 Flushed Seal Arrangements A flushed seal arrangement is fitted in order to cool the seal area It is important that The flush is correctly connected
13. 6 Spacer Bearing 37 Spacer Rotor Alignment 38 Nut Bearing 39 Bearing s Rear 40 Spacer Bearing 41 Nut Bearing 42 Lip Seal Bearing 43 Gear 44 Torque Locking Assembly 45 Plug Description Plug Sight Level Gasket Filler Plug Oil Gasket Operating Manual 47 Operating Manual Exploded Pump Drawing and Parts List 14 4 D6 Item Description 1 Gearcase 2 Dowel 3 Stud Gearcase 4 Nut Gearcase Stud 5 Washer Gearcase Stud 6 Cover Gearcase 7 Screw Rear Cover 8 Lip Seal Drive End 9 Shim 10 Rotorcase 11 Wearplate 12 Stud Wearplate 13 Nut Wearplate 14 O Ring Front Cover 15 Cover Rotorcase 16 Hex Head Screws Front Cover 17 Washer Front Cover 22 Screws Front Seal Carrier Short 23 Screws Front Seal Carrier Long 24 Lip Seals Gland End 25 Rotors 26 O Ring Rotor Sealing Shaft End 27 Torque Locking Assembly 28 Rotor Cap 29 O Ring Rotor Cap Small 30 O Ring Rotor Cap Large 31 Screw and Washer Rotor Cap 32 Kay 33 Shaft Drive 34 Shaft Auxiliary 35 Bearing s Front 36 Spacer Bearing 37 Spacer Rotor Alignment 38 Nut Bearing 39 Bearing s Rear 40 Spacer Bearing 41 Nut Bearing 42 Lip Seal Bearing 43 Gear 44 Torque Locking Assembly 45 Plug Description Plug Sight Level Gasket Filler Plug Oil Gasket Operating Manual 48
14. F PRESSURISED ADHESIVES E G PERMABOND BEARING NUTS ADJUSTMENT NUTS RELEASES VAPOUR AT ROOM TEMPERATURE OIL AND GREASE OIL GENERAL LUBRICATION SKIN AND EYE IRRITANT GREASE PRODUCT SEALS TIMING GEARS GENERAL LUBRICATION PLASTIC COMPOUNDS PTFE PTFE O RINGS LIP SEALS GLAND POLYPROPLYENE PVC PACKING POLYPROPLYENE GLAND RELEASES FUMES WHEN HEATED GUARDS PVC GLAND GUARDS ELASTOMERIC COMPOUNDS ALL O RINGS LIP SEALS NITRILE EP VITON NITRILE NEOPRENE POLYURETHANE ROTORS KNOWN RELEASES FUMES WHEN HEATED AS RUBBER AND URETHANE ARAMID FIBRE GLAND PACKING PAINT EXTERNAL PUMP SURFACES EMMITS HARMFUL DUST RELEASES FUMES WHEN HEATED RELEASES DUST AND FUMES IF MACHINED TREAT AS A FIRE HAZARD Operating Manual 2 0 Unpacking Handling and Storage Toavoid any problems on receipt of your pump always use the following procedure 2 1 Documents 1 Checkthe delivery note againstthe goods received 2 If the pump has been delivered with an electric motor check that the motor instructions are available 2 2 Unpacking Care mustbe taken when unpacking the pump and the following stages must be completed 1 Inspectthe packing for any possible signs of damage in transit 2 Carefully remove the packing away from the pump 3 Inspect the pump for any visible signs of damage 4 Clean away the packing from the pump port connections
15. NOS pimps Series D Ductile Iron Positive Displacement Rotary Lobe Pumps Operating Manual M 103 0301 Alfa Laval Pumps Ltd Birch Road Eastbourne East Sussex BN23 6PQ Tel No 01323 412555 Fax 01323 412515 EC DECLARATION OF INCORPORATION We hereby declare that the following machinery is intended for installation into a machine or to be assembled with other machines into a machine t must not be put into service until the machinery into which itis incorporated has been declared in conformity with the provisions of the Machinery Directive 89 392 EEC amendments 91 368 EEC 93 44 EEC 93 68 EEC Machine Description Rotary Lobe Pump Type Size Serial Number This machinery has been designed and manufactured in accordance with the following transposed harmonised European Standards EN292 Parts 1 and 2 1991 Safety of Machinery Basic Concepts general principles for design EN294 1992 Safety distances to prevent danger zones being reached by the upper limbs ISO9001 2000 Quality Management System A technical construction file for this machinery is retained atthe above address Signed eod Authorised Person Date Name P SWEET Position QUALITY MANAGER Alfa Laval Pumps Ltd Birch Road Eastbourne East Sussex BN23 6PQ Tel No 01323 412555 Fax 01323 412515 EC DECLARATION OF CONFORMITY We hereby declare that the following machinery conforms to the machinery directive
16. Pump Pump Unit Pump complete with Drive Unit Pump Model Bareshaft Pump Pump with Drive Unit KG KG D4 0079 D4 0095 D4 0140 D5 0168 D5 0200 D5 0290 D6 0353 D6 0420 D6 0600 The above weights are for guidance only and will vary depending upon the specification of the pump baseplate and drive unit Operating Manual 3 5 Pump Displacement and Capacities The following table details the pump capacities for the pump models This figure will change depending upon speed pressure temperature and product being pumped Displacement Maximum Maximum Capacity litres rev Speed at Maximum Speed Water m hr rpm D4 0079 D4 0095 D4 0140 D5 0168 D5 0200 D5 0290 D6 0353 D6 0420 D6 0600 10 Operating Manual 4 0 System Design and Installation 4 1 System Design Advice When designing the pumping system Do Do Do Do confirm with the supplier the Net Positive Suction Head NPSH requirements forthe pump as this is crucial for ensuring the smooth operation of the pump and preventing cavitation avoid suction lifts and manifold common suction lines for two pumps running in parallel as this may cause vibration or cavitation Discharge Line Plan View Suction Line protect the pump against blockage from hard solid objects e g nuts bolts etc Also protect the pump from accidental operation against a closed valve by using one of the following methods relief valves pressure swit
17. See overleaf A compatible flushing fluid is used The fluid is supplied at the correct pressure and flow rate The flush is turned on at the same time prior to starting the pump and turned off atthe same time after stopping the pump 17 5 4 Connecting the Flush The following equipment is strongly recommended when using a flushing system Control valve and pressure gauge to enable the correct flushing pressure to be obtained and monitored A constant flow valve can be used Isolation valve and check valve so that the flush can be turned off and to stop any unwanted substances flowing in the wrong direction A method of visibly indicating flushing fluid flow e g using a tun dish Operating Manual 5 5 Flushing Pipework Layout This suggested arrangement is for single mechnical seals If the pump is fitted with double mechanical seals or packed glands the pressure gauges and control valves should be fitted on the outlet side of the system SUGGESTED VISIBLE INDICATION OF FLOW ee CONTROL E p VALVE 5 E tq e PRESSURE FS Il GAUGE FLUSH OUTLET PIPEWORK amp FITTINGS TO WASTE NOT SUPPLIED DOUBLE MECHANICAL SEAL PACKED GLAND ONLY Note The pipework and fittings are not supplied with pump a PRESSURE CONTROL VALVE Ok ae rm CHECK VALVE XK i ISOLAT ON X VALVE FLUSH INLET 18 Operating Manual 5 6 Flush
18. above procedure for the rear set of bearings but in this case torque up the lock nut until the spacer can be just moved by finger pressure alone Bearing Assembly Note Direction of Tapers li Gear End Spacer Spacer 10 10 Shaft Replacement Gearboxes are assembled with the top shaft bearing located against a machined surface in the bearing housing and the bottom shaft bearings butting against a spacer fitted into the front bearing housing When a new gearbox is being built this spacer is initially oversized such that the axial displacement in the rotor abutment shoulders can be measured and the appropriate spacer fitted orthe existing spacer groundto suit When rebuilding a used gearbox the axial displacement should be checked however it will normally be within tolerance 0 012mm Rotor Abutment Alignment Rotor or Abutment Block Note The axial displacement can be in either direction as long as it is within tolerance Operating Manual Replace shaft abutment spacer into the front bottom bearing housing of the gearcase between the front bearing and the housing Fit auxiliary shaft into gearcase Fit drive shaft into gearcase Fit seal retainers to the gearcase without silicon sealant at this stage and torque the cap screws to their recommended value Fit rotors or shaft abutment blocks to the shafts and torque the rotor torque locki
19. acement Page No 19 20 Contents 11 0 T3 11 2 11 3 11 4 11 5 14 6 12 0 13 0 13 1 13 2 13 3 14 0 14 1 14 2 14 1 14 2 Product Seal Removals and Fittings Single Mechanical Seal Single Flushed Mechanical Seal Double Mechanical Seal Packed Gland Packed Gland with Flush Mechanical Sewage Seal Faults Causes and Remedies Technical Data Pump Information Chart Seal Specification Chart Torque Specification Chart Exploded Drawings and Parts List Priming Adaptor Ports D4 Pump D5 Pump D6 Pump 1 0 General 1 4 Pump Limits of Application or Use This range of pumps has been designed to offer awide span oftransfer duties throughout industry where the use of stainless steel for pumphead components is not essential Pressures of upto 15 bar speedsto750rpm and temperatures to 200 C can be obtained on this range of pumps depending on pump model size These conditions cannot always be obtained simultaneously The model type size will be shownonthe nameplate positioned onthe pump The pump pump unit will have been selected from the pump users specific application when known and the pump serial number will relate to this If the user has not specified the pumping application or needs to change it itis important to confirm that the materials of construction and product seals are compatible with the pumping application and thatadequate NPSHis available It is therefore strongly recommended that th
20. aining nuts and ease the housing away from the rotorcase Remove the rotorcase retaining nuts and tatp the rotorcase forwards with a soft mallet until it clears the locking dowels If the pump is fitted with mechanical seals care must be taken to support the rotorcase as it comes off the dowels otherwise the mechanical seals may be damaged Operating Manual Between the rotorcase and gearcase preshaped plastic shims are used to adjust the rotor clearances These must be replaced exactly as removed otherwise excessive wear or damage may occur to the rotors and or rotorcase Once the rotorcase is removed the seals gland packing can be examined 28 Operating Manual 9 4 Replacing the Front Gearcase Seals Follow the procedure for the removal of rotors and rotorcase Remove the product seal Three socket head screws retain the seal carrier once removed the carrier can be extracted As silicon sealant or a gasket is used to seal the faces the carrier may have to be eased off carefully with a lever Once the carriers are removed from the pump the seals can be pressed out and replacements pressed in using a suitable dolly Ensure the surface area which the seal will run on is free from scratches if the surface is scratched clean up damaged area with a fine grade abrasive cloth Ensure that all traces of abrasive material are cleaned away before refitting the new oil seals Note It is advisable at this poin
21. ch current monitoring device Install a motor current sensing device which automatically reverses the pump when an overload or jam is detected Note This is not recommended when non return valves are fitted 11 Do Do Do Do fit suction and discharge pressure gauges to monitor pressures for diagnostic purposes install non return valve to prevent turbining when high pressures are applied to the pump whilst it is not in use Valves are also recommended if two pumps are to be used on manifold common discharge lines make the necessary piping arrangements if flushing is required for the seal provide a hose cleaning facility to assist maintenance ensuring the drive unit meets the specification for hose cleaning 4 2 Pump and Base Foundations Depending on your requirements the pump and drive if supplied may arrive mounted on a baseplate Our standard baseplates have pre drilled fixing holes to accept base retaining bolts To provide a permanent rigid support for securingthe pump unit a foundation is required this will also absorb vibration strain or shock on the pumping unit Foundation Size The foundation should be approximately 150mm longer and wider than the mounting base of the unit The depth of the foundation should be proportional to the size of the pump unit pump complete with drive and baseplate For example a large pump unit foundation depth should be at least 20 times the diameter
22. e user contactthe supplier quoting pump model size serial number and system details e g product pressure flow rate 1 2 Pump Duty Conditions The pump should only be used for the duty for which it has been specified The operating pressure speed and temperature limits have been selected at the time of order and MUST NOT be exceeded for the pump These details are stated on the original documentation and if notavailable may be obtained from your supplier quoting pump model and serial number Operating Manual 1 3 Noise Levels Undercertain operating conditions pumps and or drives and or the systems within which they are installed can produce sound pressure levels in excess of 85dB A When necessary personal protection against noise should be taken to safeguard the hearing of persons who are likely to be in close proximity to the equipment Please contact Alfa Laval Pumps for further information if necessary 1 4 Utility Requirements Electrical Supply This pump may be supplied bareshaft or coupled to a drive unit for which a drive unit electrical supply will be required Note The pump may be also driven by a diesel drive unit Water Supply Additional water supplies may be required ifthe pump is fitted with a product seal flushing arrangement Consult your supplier for flush fluids compatible with products pumped Operating Manual 1 5 Safety Precautions Warning Signs All warnings in this
23. e Instructions Loosen the socket head cap screw and remove the rotor cap ensuring that the two sealing O rings are not lost If the rotor cap does not release easily it can be removed by gently screwing a Suitable screw into the thread in the centre hole of the rotor cap Loosen the TLA in several stages and in a diametrically opposite sequence The loosened TLA can now be removed To extract the TLA from the rotor only remove the two screws which are fitted with washers carefully screw 8mm x 50mm bolts into the holes these holes have only 3 5 threads and pull out the TLA 24 Operating Manual 8 3 Rotor Retention Torque Locking Assembly Rotor Clamp TES Access to TLA through slots Rotor Torque Values for Rotor Torque Locking Assemblies Torque Nm Ibft 4 4 3 0 8 5 6 3 14 0 10 3 25 Key Size mm 9 0 General Maintenance 9 1 Before Dismantling the Pump Before starting to dismantle the pump Always Purge the pump and system if any noxious products have been pumped Isolate pump drive unit from all power and control supplies Close pipework valves to isolate the pump Disconnect gt gt e gt the pump from the drive unit Read this section first before continuing to dismantle the pump Operating Manual 26 Operating Manual 9 2 Removing the Rotors il 27 Before starting to dismantle the pumphead isolate the driver pump from all
24. ed Seal Housing Connections Pump Model Single Double Packed Mech Seal Gland D4 1 8 1 4 D5 1 8 1 4 D6 1 8 1 4 All connections BSPT or NPT as specified at the time of order 5 7 Flushing Fluid The choice of flushing fluid is dependant upon the pumping media and duty conditions i e pressure and temperature Usually water is used for cooling or flushing water soluble products For advice on selecting a suitable flushing fluid please contact the supplier 19 5 8 Flushing Pressure and Flow Rate Single Mechanical Seal 0 5 Bar maximum Any further increase in pressure will result in lip seal failure Double Mechanical Seal Packed Gland Seal 1 0 bar higher pressure compared to the discharge pressure of the pump Ifthe discharge pressure fluctuates set the flushing pressure to suit the maximum condition For guidance the pressure at the seal is approximately of the pumping pressure The flushing flow rate must be adequate to ensure that the temperature limitation of the seals is not exceeded Contact your supplier for further information on the recommended flow rate for the product seal fitted 6 0 Start up Shut Down and Cleaning in Place 6 1 Pump Start up Checklist is Is the location of the stop button clear Has the pipework system been flushed through to purge welding slag and any other hard solids Have all obstructions been removed from the pipework or pump Are the pump con
25. ekly to prevent bearing and gear damage All associated ancillary equipment should be treated similarly If the pump is fitted with a diesel petrol engine it is advisable to disconnect the pump and run the engine every two months Operating Manual 3 0 Description of Pump or Pump Unit 3 1 General Pump Description The pump supplied is a positive displacement pump which may be supplied with or without a drive unit see below The drawing below indicates various parts of the pump Rotorcase A Pump Drive Unit Coupling Guard Houses Coupling Pump with Drive Unit 3 2 Principle of Operation The rotors are timed such that when they rotate no contact occurs The direction of flow is As the rotors continue to rotate the product is reversed by changing the direction of rotation transferred around the outside of the rotorcase of the pump drive shaft The pumping principle to the discharge side is as follows The rotors have just come out of mesh creating a reduction in pressure in the chamber which is then filled with product The rotors lobes go into mesh and the product is discharged from the pump The product is contained in the rotorcase chamber 2 Operating Manual 3 3 Pump Dimensions
26. hlighted Your weekly schedule should include e Checking the oil level in the gearcase Checking the mechanical seals for leakage and replacing as necessary Geasing the mechanical sewage seal if fitted Adjusting the packed glands to control leakage Checking the oil seals for leakage e Check pumping pressures Operating Manual 7 2 Recommended Spare Parts The following table details the recommended spare parts which should be retained within your maintenance stock Part Description Quantity Lip Seal Drive End O Ring Front Cover Lip Seal Gland End Rotors O Ring Rotor Sealing O Ring Rotor Cap Product Seals 22 Operating Manual 7 3 Maintenance Tools Dismantling and Assembly of the Pumphead You will need Allen keys Spanners Socket set Wooden wedge Soft mallet Cleaning hose Silicon grease Torque wrench Rotor clamp tool supplied with pump Dismantling and Assembly of the Gearbox You will need A Work Shop equipped with A heavy duty vice A press and pressing tools Lifting gear Induction heater A method of lubrication collection Lever soft ended Wooden wedge C spanner Liquid gasket Permabond 145 or equivalent Torque wrench 23 Pump Head Rotor Cap 8 0 Disassembly Rotor retention on all pumps in the DRM range is by Torque Locking Assembly TLA with flush fitting rotor caps The rotor spline area
27. holes 9 The rotorcase can now be refitted whilst at the same time locating and tightening the seal housing nuts 38 Operating Manual 11 3 Double Mechanical Seal us e Stationary Face O Ring Stationay Face Rotary Face Shaft O Ring Wave Spring Dive Ring LAN IS uw Wave Spring ANI AE SINK Shaft O Ring Rotorcase i DANIL A Gearcase Rotary Face Side INS Side Stationary Face Gasket Stationary Face O Ring Seal Housing Note The drive ring chamfer must Fitting the Double Mechanical Seal be on the gearcase side of the shaft The seal consists of two rotary faces which are sealed to the shaft by O rings Rotation is provided by socket set screws which tighten 2 Lightly lubricate the O rings and shaft onto the shaft The two stationary faces are end with silicon grease food quality if located in the rotorcase and seal housing bores necessary Rotation is prevented by pins and cast lugs 3 Wave spring s provide a face to maintain face to face contact As seal housing attached to the rotorcase encloses and sets the seal 4 Locate O rings into rotary faces Seal faces are brittle Take extreme care when handling 5 Carefully fit the seal housing with stationary face onto the shaft Removing the Double Mechanical Seal 6 Push the rotary assembly onto the shaft until it sets against the seal housing stationary face WY 1 Use solvent to wipe the lapped surface of
28. il Mobilplex 48 Mobil Mobillux NO2 42 Operating Manual les Causes and Remed 12 0 Faults S1HOd LATLNO ANY LIINI Sdlifid SHL LV SONIGWAY JANSSIYd INV3S IIS NO 9NDIV IL Ag GALSISSV AT1V339 38 TIIM SISON9VIG DLL SI9uduoo veu 4 82 weuwesSudunduow J 1948 dund 01y eemssexd Anp pue paei yoyo Le weueeBudundopeueoeuonee 1 T T ST LLL emen Bus _ lomedid poddng sumy uoisuedxe 10 sedid ejqiej y4 sedid Jo jueuuBije xoeuo secono pae usen ioa A E A E S E m L L L b emm L L L L 2 suisse tamu m A E A a a A m TT e eroana nau nun er won m 58 1 TT l L L j ri T TRL vous eum ELM 0 wem pusjB Bujas pis peqiosqe ueuM S3 Snvo Jemod syeoysoao seuna sies eBuuuosiq 9AISS82X3 jojoW dung duind Janbe sindur Jemod popuued pue uo Ajsoosia pessejoul Jo paye 2euo einjereduie jonpoud esee12ed peeds eonpeyy ususe eonpeJ pue uonein amp uoo euj Ajddns Adug peetj uonons eseeiou 1eyeureip aur jddns aseeiouj uopneiqi 3 OSION 43 Operating Manual 13 0 Technical Data 13 1 Pump Information Chart Suction amp Discharge Connections Displacement Connection Size Litres US gal international stds Differential Pressure Max Speed S
29. iously been shimmed replace the old shims in their original positions Alternatively if new shims are to be fitted the shimming process commences with too few shims Fit the rotorcase and torque up the gearcase nuts fit the rotors and tighten to the recommended torque With too few shims fitted measure the back clearances the clearance between the back of the rotors and rotorcase and determine the additional shimming required to bring the clearance within tolerance Note For the correct clearance dimensions please contact your supplier Fit the additional shims and recheck the clearances If necessary repeatthe above exercise until the clearances come within tolerance Care should be taken when sliding the rotorcase over the shafts so as not to damage the mechanical seals iffitted When fitting the shims ensure that similar clearances are achieved both top and bottom of the rotorcase Operating Manual 9 6 Front Cover Reversal The front cover of all pumps inthe series D range is ofa flat and symmetrical design thus making it reversible Therefore when the inside face of the front cover becomes worn it may be reversed In due course both sides will become worn and the cover will have to be replaced Isolate the driver pump from all power and control supplies If any noxious products have been pumped the system should be purged Ensure isolating valves to the pump are closed Loosen and remove the front c
30. l is to be reused care should be taken when extracting it not to damage the sealing edge otherwise a new lip seal should be fitted To refit a seal it should be pressed evenly into the hole and a flat plate or dolly used to drive it home 10 5 Fitting the Timing Gears 1 Fitthe rotors to the shafts to establish the timing 2 Check that the bearing lip seal is fitted Check that the boss on the back of the gearis smooth and smear some lubricant onto it 3 Slide on the gears Where gears are marked as pairs they should be refitted with the timing marks aligned 4 Fit the torque locking assemblies and torque one ofthem up Adjustthe timing before tightening up of the last gear 34 Operating Manual 10 6 Shaft Removal 1 Remove rotorcase front cover rotor and rotorcase 2 Remove product seals 3 Remove the gearcase rear cover timing gears and drain lubricant 4 Remove the gearcase front seal retainers and seals 5 Theshaftassemblies can now be removed through the front end of the gearbox a softfaced mallet may be used to tap them out The top chamber can now be completely drained Ensure that the spacer located in the front bottom shaft bearing housing is retained for refitting 10 7 Bearings General The DRM range of pumps utilise taper roller bearings which are arranged in two sets of double bearings front and back assembled with individual spacers Refer to the exploded diagrams at the
31. lectrical Ensure that there is an Supply adequate electrical supply close to the pump drive unit This should be compatible with the electric motor selected 12 Operating Manual 4 4 Coupling Misalignment Tao Parallel Misalignment When installing the pump and drive unit it is essential to ensure that the coupling is not twisted during installation The main cause of F misalignment is by fitting the baseplate to an uneven surface Angular Misalignment Check the maximum angular and parallel i allowable misalignments for the couplings before operating the pump Recommended Coupling Type Maximum Parallel Maximum Angular Misalignment Misalignment David Brown t1 5 Nylicon Flexible Per Gear in Mesh William Kenyon Flexilok Fenaflex Flexible Tyres Note The above table indicates the common coupling types used on the pump ranges Details for other coupling types will be available on request 13 Operating Manual 4 5 Pulley Belt Tension Adjustment An incorrectly tensioned belt will cause belt slip and short belt life An excessively tensioned belt will overload both belts and bearings Always use a belt tension gauge fo setting up Isolate the drive unit and pump from all power and control supplies before attempting to work on adjusting the belts 1 Measure the span length 2 Calculate the required deflection x 100mm span length 1mm deflection therefore 400mm span length 4m
32. ludge Max Speed Water Max Capacity Water rev 100 rev mm inches D4 0095 D4 0140 D5 0200 D5 0290 100 150 optional 6 optional D6 0420 150 6 D6 0600 150 6 13 2 Seal Specification Chart Gland Packing Section Square Packed Glands Standard Pump Model Number of Rings per Seal rev min GE Packing Section Square rev min m h l sec Number of Rings per Seal Operating Manual 13 3 Torque Specification Chart Front Cover Screws Front Seal Carriers and Rear Covers Torque 25 Nm 19 Ibft Key Size 6mm Wearplates Torque 8 Nm 5 9 Ibft Spanner Size 10mm Shaft Sleeve Retaining Screws D4 Torque 4 Nm 2 9 Ibft Key Size 3mm D5 amp D6 Torque 14 Nm 10 3 Ibft Key Size 4mm 44 Operating Manual 14 0 Exploded Pump Drawing and Parts List 14 1 Priming Adaptor Ports D4 0140 Priming Adaptor Option unis Priming Adaptor Gasket Bolt Washer Nut Blanking Plug D4 0095 Priming Adap tor Option si Esc Priming Adaptor Gasket Bolt Washer Nut Rotorcase Rectangular Ports 45 Exploded Pump Drawing and Parts List 14 2 D4 Item OONOOARWHND Description Item Gearcase 46 Dowel 47 Stud Gearcase 48 Nut Gearcase Stud 49 Washer Gearcase Stud 50 Cover Gearcase Screw Rear Cover Lip Seal Drive End Shim Rotorcase Wearplate Stud Wearplate Nut Wea
33. m deflection 3 Refer to the table for recommended minimum and maximum deflection force for small pulley diameter range To convert Newtons to pounds force multiply by 0 2248 A B To convert Newtons to kilogrammes force multiply by 0 1020 Belt Small Pulley Recommended Section Diameter Deflection Force 4 Usea belt tension gauge with the figures Range Newtons to determine the belt adjustment required 56 7 11 5 Belt tension adjustment is achieved by XPZ adjusting the nuts on the pedestal frame phe His 75 80 6 Finally checkthatall nuts are re tightened 85 95 and the belts can move freely by hand rs depending upon pump size and system 6 24 design XPA 80 125 18 27 SPA 132 200 22 31 7 Ensure the pulleys are kept vertically and horizontally to each other and aligned as per diagrams A and B Note The above table indicates the common pulley types used on the pump ranges Details for other pulley types will be available on request 14 Operating Manual 4 6 Pipework All pipework must be supported The pump must not be allowed to support any of the pipework weight Remember Always Have Use Pipework supports must also support the weight of the product being pumped Short straight suction lines to reduce friction losses in the pipework thereby improving the NPSH available Long radius bends wherever possible Provide Isolating valves on each side of the pump
34. manual are summarised on this page Pay special attention to the instructions below so that severe personal injury or damage to the pump can be avoided Personnel performing installation operation General safety instructions are preceded by this symbol AN Electrical safety instructions are preceded by this symbol and maintenance of the pump must have the relevant experience required A Take great care when using caustic Installation ERPB O xo D 9 ze o 3 pPPPPPPPR Maintenance PPPPP agents Always observe the technical data The pump must be electrically connected by authorised personnel See the motor instructions supplied with the drive unit Never start in the wrong direction of rotation with liquid in the pump Never put your hands or fingers inside the port connections Always observe the technical data Never touch the pump or the pipelines when pumping hot liquids Never stand on the pump or pipelines Never run the pump with the suction side or the pressure side blocked Always handle toxic and acidic liquids with great care Never put your hands or fingers inside the port connections In certain circumstances the gearbox and pump may become very hot Never touch the pump without wearing protective clothing Always observe the technical data Always disconnect the pump from the drive unit and power supply when servicing the pump The
35. n below p n Master lobe f y x Master lobe EN R Correct timing has been achieved when the pump rotates freely without contact taking place between the rotors this should always be checked prior to running the pump Replace the torque locking assemblies Refer to section 8 1 on page 23 for full details Before refitting the front cover examine the O ring and replace it if damaged Fit front cover and tighten the nuts up to the recommended torque values 9 9 Wearplates Replacing Wearplates All pumps in the series D range can be fitted with wearplates When worn the wearplates can be replaced thus increasing the life of the pump Wearplates can be replaced without removing the rotorcase but access to the wearplate retaining nuts may be increased if the rotorcase is removed Removing Old Wearplates 1 Remove the front cover and rotors as described f considered necessary remove rotorcase Loosen and remove the wear plate stud retaining nuts from the rear ofthe rotorcase Next the wearplates with the studs still attached may be removed fromthe front of the rotorcase where the wearplates will be seated Fitting New Wearplates Operating Manual Before fitting new wearplates thoroughly clean the inside of the rotorcase where the wearplates willbe sealed In addition wipe clean the rear face of the new wearplates The new wearplates will be supplied with the studs already attached Just prior t
36. nections and pipework joints tight and leak free Is there lubrication in the pump and drive unit If your product seals require flushing has the flushing supply been fitted Are the pipework valves open Are all safety guards in place Start then stop the pump is the product flowing in the correct direction Are the pump speed pressure settings below the pump maximum limitations n LLLI LI LI UI oD 0 LJ u L Operating Manual LL D PIE EL DL 0 U Lis All answers should be Yes before proceeding If there are any pumping problems refer to the fault finding chart 20 Operating Manual 6 2 Pump Shut Down Procedure 1 Turn the pump off 2 Isolate the pump drive unit from all power and control supplies 3 Close the pipework valves to isolate the pump 4 Ifthe pumpis to be dismantled referto the dismantling section 6 3 Direction of Rotation The direction of flow is dictated by the direction of rotation of the drive shaft Reversing the direction of rotation will reverse the flow direction Top and bottom shaft drive pumps have opposite flow directions as illustrated Top Shaft Drive Position Discharge lt a Suction 21 Suction Bottom Shaft Drive Position 7 0 Maintenance and Inspection 7 1 Maintenance and Schedule It is advisable to install pressure gauges either side of pump so that any problems within the pump pipework will be hig
37. ng assemblies to the recommended value Using a depth micrometer measure from the front face of the bottom rotor to the front face of the top rotor and record the axial displacement of the rotor abutment shoulders When measuring off a pair of rotors it is important to compensate for any small differences there may be in the rotor lengths The axial displacement should be less than 0 012mm if itis not the bottom shaft should be removed and the spacer ground or an appropriate spacer fitted to give a axial displacement of not greater than 0 012mm Once both shaft shoulders are within tolerance of each other remove both seal retainers fitthe frontoil seals apply silicon sealant to the retainer face and torque up Recheck to ensure alignment With the shafts installed the timing gears and front end of the pump can be refitted The pump should now be timed as previously described 36 Operating Manual 11 0 Product Seals Removal and Fitting 11 1 Single Mechanical Seal a Stationary Face O Ring Stationary Face Rotary Face Shaft O Ring Wave Spring Drive Ring The seal comprises of a rotary face which is sealed to the shaft by an O ring A wave spring s provide a force to maintain face to face contact Rotation is provided by socket set screws which are tightened onto the shaft The stationary face is located in the rotorcase and is prevented from rotating by three pins Seal faces are extremely brittle
38. o fitting the wearplates apply silicon sealant or similar to the wearplate studs Insert the new wearplates through the front of the rotorcase ensuring that the studs pass through the holes in the rear of the rotorcase Assemble nuts to the studs at the rear of the rotorcase and tighten to a torque of 8Nm 5 9 Ibft 32 Operating Manual 10 0 Gearbox Components 10 1 Timing Gears Each pump is fitted with a pair of timing gears which are located in the rear of the gearcase and ensure synchronisation of the rotors such that under normal working conditions they will not contact one another The timing gears on pumps in the D range are retained using Torque Locking Assemblies TLA similar to those used to retain the rotors The method of correctly tightening the TLA s is the same as for the rotors as previously described p Ew Timing Gears Torque Key Size Nm lb ft mm 33 Measurement Point Point 10 2 Timing Adjustment The rotor timing synchronisation is set up in the factory If the rotors become unsynchronised they may be retimed using the following procedure The cause of the fault should be established and eliminated before proceeding To adjust the timing of the rotors first remove the gearcase end cover once the cover is removed the timing gears will be exposed
39. of the foundation bolts Bolt Location Dimensions The location and sizes of the relevant bolting down holes can be provided on a certified drawing from your supplier Typical Foundations Bolts The drawing below shows two methods for foundation bolt retaining The sleeve allows for slight lateral movement of the bolts after the foundation is poured Use rag or paper to prevent the concrete from entering the sleeve while the foundation is poured A minimum of 14 days is required to allow the curing of the concrete prior to operation D Diameter of foundation bolts Waste put around bolt before pouring concrete Foundation surface left rough to anchor grout MUN mip J Lug welded to boit head Operating Manual 4 3 Installation Before the pump is installed it is advisable to consider the following Always Ensure that the mounting surface is flat to avoid distortion of the baseplate This will cause pump motor shaft misalignment and pump motor unit damage Check pump shaft to motor shaft alignment once the baseplate has been secured and adjust as necessary TN Baseplate Fixing 7 Holes Note Always allow at least one metre for pump access maintenance all around the pump Weight Consider the weight of the pump drive and lifting gear requirements E
40. over retaining screws andremove the front cover In the case of D5 and D6 pumps loosen and remove the screws which hold the front cover to the hinge Be sure to retain the washers fitted under the screw heads Thoroughly clean the front cover Inspect O ring and replace if necessary Before replacing front cover simply reverse it suchthatthe unworn side faces the pump Inthe case of the D5 pumps ensure that the cover is orientated such thatthe hinge fixing holes line up with the hinge Inthe case of D5 and D6 pumps refit the hinge to the cover by refitting the hinge retaining screws make sure thatthe washers are refitted under the screw heads Ensure thatthe ends of the hinge retaining screws are flush with the inside of the front cover when fully tightened Fit front cover and tighten retaining screws to the recommended torque values 30 Operating Manual 9 7 Removal of Rear Gearcase Cover and Replacement of Seal 1 Isolate the motor remove any coupling or Vee belt guards If the pump is direct coupled it will be necessary to disconnect the coupling and removethe pumpfrom the baseplate before removing the gearcase cover Ifthe pumpis beltdriven releasethetension onthe belts and remove them remove the pulley and drive key Drain the oil from the pump Remove the retaining screws and then remove the gearcase cover by sliding it along the drive shaft As the cover is sealedtothe gearcase with a liquid gasket
41. pump must never be hot when servicing it The pump and pipelines must never be pressurised when servicing the pump Never put your hands or fingers inside the port connections Study this manual carefully 1 6 Health and Safety Information Potential Safety Hazards The following section gives information on handling storage and disposal of parts and materials used in the pumps which may be considered hazardous to health Please pass this information on to your Safety Officer he may need it to comply with Health and Safety and COSHH regulations Electric motors the pump may have an electric motor fitted ensure that the relevant fire equipment is available The information contained here is brief Operating Manual General First Aid If potentially hazardous substances are accidentally inhaled or skin or eyes contaminated then the following basic precautions should be taken Inhalation Remove to fresh air Skin Wash with soap and water Eyes Flush with water seek medical attention In all cases if symptoms persist seek medical attention SILICON SEALANT GEARBOX SEAL RETAINERS REAR RELEASES VAPOUR AT ROOM COVER GENERAL SEALANT TEMPERATURE SEALANT RED HERMETITE ANTI SEIZE COMPOUNDS BEARINGS GEARBOX SEAL RETAINERS REAR COVER GENERAL SEALANT RELEASES VAPOUR AT ROOM TEMPERATURE HIGHLY FLAMMABLE TREAT AS FIRE HAZARD APPLIED FROM AEROSOL RELEASES VAPOUR DISPOSH OF CONTAINER AS I
42. rear of the manual 10 8 Bearings Removal To remove the bearings undo the notched bearing nut using a C spanner the bearing assembly can now be dismantled The bearing cones are shrunk onto the shaft and will require pressing off 10 9 Fitting Bearings to Shaft 1 Load shaft into vice in a vertical position and apply anti seize compound to the bearing diameters 2 Working first on the front set of bearings use an induction heater or oil bath to heat the front bearing cone to 110 C Pass the bearing over the rear bearing diameter and ensure a positive fit on the front bearing diameter against the shaft shoulder The bearing taper should be towards the gear end of the shaft 35 10 Rotor End Locate outer shell of bearing onto the cone just fitted Locate bearing spacer onto shell justfitted Locate rear bearing shell of front set of bearings onto the spacer Heat rear bearing cone to 110 C and fit to bearing diameter The taper should be towards the rotor end of the shaft Allow bearings to cool Locate shaft in vice in horizontal position Apply Permabond grade 145 sealant or equivalentto the shaft front lock nut thread and screw front lock nut onto the shaft Whilst continuously rotating both bearings and spacer torque up the bearing lock nut until the spacer cannot be moved radially off the shaft centre line by finger pressure alone but can be moved with a light blow of a hammer Repeat the
43. rplate O Ring Front Cover Cover Rotorcase Hex Head Screws Front Cover Washer Front Cover Screws Front Seal Carrier Short Screws Front Seal Carrier Long Lip Seals Gland End Rotors O Ring Rotor Sealing Shaft End Torque Locking Assembly Rotor Cap O Ring Rotor Cap Small O Ring Rotor Cap Large Screw and Washer Rotor Cap Kay Shaft Drive Shaft Auxiliary Bearing s Front Spacer Bearing Spacer Rotor Alignment Nut Bearing Bearing s Rear Spacer Bearing Nut Bearing Lip Seal Bearing Gear Torque Locking Assembly Plug Operating Manual Description Plug Sight Level Gasket Filler Plug Oil Gasket Operating Manual M Cre O 46 Operating Manual Exploded Pump Drawing and Parts List 14 3 D5 Item Description 1 Gearcase 2 Dowel 3 Stud Gearcase 4 Nut Gearcase Stud 5 Washer Gearcase Stud 6 Cover Gearcase 7 Screw Rear Cover 8 Lip Seal Drive End 9 Shim 10 Rotorcase 11 Wearplate 12 Stud Wearplate 13 Nut Wearplate 14 O Ring Front Cover 15 Cover Rotorcase 16 Hex Head Screws Front Cover 17 Washer Front Cover 22 Screws Front Seal Carrier Short 23 Screws Front Seal Carrier Long 24 Lip Seals Gland End 25 Rotors 26 O Ring Rotor Sealing Shaft End 27 Torque Locking Assembly 28 Rotor Cap 29 O Ring Rotor Cap Small 30 O Ring Rotor Cap Large 31 Screw and Washer Rotor Cap 32 Kay 33 Shaft Drive 34 Shaft Auxiliary 35 Bearing s Front 3
44. t to check for bearing end play as this may be the cause of the seals leaking 29 Front Seal Carriers Before replacing the seal carriers clean the old silicon sealant if used from the rear face of the carrier and from the front face of the gearcase Coat the rear face of the carrier with new liquid gasket slide into position and replace the three socket head screws It must be noted that one of the three screws is longer this should be inserted in the hole which aligns with the largest hole in the gearcase Tighten the screws evenlytothe recommended torque value Reassemble the seals and rotorcase see the relevant sections for refitting procedure S Front Seals Large Holes Longer Socket Head Screws 9 5 Fitting and Shimming the Rotorcase When fitting a rotorcase correct shimming is critical Shims are fitted between the rotorcase and gearcase and are used to control the back clearances between the rotor and rotorcase Plastic colour coded shims are used onall series D pumps If the pump has previously been shimmed the old shims may be reused provided they are replaced in their original positions Itis essential that equal shimming is used both top and bottom ofthe rotorcase to ensure that equal clearances are maintained across the rotor faces Toreassemble the rotorcase the following step by step procedure should be used Check the seals are correctly fitted If the rotorcase has prev
45. the seal faces perfectly clean being extremely careful not to scratch the faces Firmly press on the O rings to the stationary faces and locate them within the rotorcase bore and seal housing 1 Using the flushing holes loosen each of the socket set screws 2 Remove the seal housing retaining nuts 7 Fit new seal housing gasket and pull back the seal housing awayfrom amp Carefully fit the rotorcase and tighten the the rotorcase seal housing nuts 3 Carefully remove the rotorcase with the 9 Ads Tighten each ofthe seal socket set screws stationary face still fitted g through the seal housing flushing holes 4 Slide the rotary faces off the shaft followed by the seal housing with remaining stationary face 39 Operating Manual 11 4 Packed Gland Arrangements Packed Gland BERR EI Dee wn oon E Shaft Sleeve O Ring Gasket Shaft Sleeve Gland Housing Spacer Gland Follower Packing Rings Ring Slinger Drip leakage is essential to prevent Fitting the Packed Gland overheating of the gland area which will cause seal failure 1 Lubricate the O ring locate in shaft sleeve and slide onto the shaft The packing rings are located within the gland housing and are tightened onto the shaft 2 Tightenupthe socket set screws ensuring sleeve by adjusting the gland follower On tha the drilled dimples are aligned with flushed packed glands a lantern ring replaces the grub screws Permabond A130 or
46. the seal set screws 2 Remove the seal housing and rotorcase retaining nuts and carefully pull off the rotorcase 3 Take care to remove the bronze bush from the rotorcase and the seal rotary assembly from the shaft 4 All seal parts can now be cleaned inspected and replaced as necessary Operating Manual mis AY 7 y SEE 7A 8 Assembly 1 Fitthe stationary sealface assembly onto the seal housing taking care to position it on the cast lugs provided 2 Slide the seal housing over the shaft ends 3 Carefully place the seal rotary assembly onto the shaft and up to the stationary face 4 Locate the bronze bush into the rotorcase bore on the three pins provided 5 Position the rotorcase on the pump and tighten up the rotorcase gearcase nuts 6 Re position the seal housing onto the rotorcase and tighten the housing retaining nuts 7 Usingthe hole provided inthe seal housing tighten the mechanical seal set screw to finally set the seal 8 Refer to the Maintenance Manual for refitting the rotors and pump front cover 9 Finally before start up the seal housing must be charged with grease and recharged periodically to ensure optimum seal performance The grease must be pumped into the seal housing until the grease appears at the shaft bore of the rotorcase Recommended grease for re charging Shell Alvania R2 Burmah Castrol LS2 Mob
47. ts Pump Displacement and Capacities System Design and Installation System Design Advice Pump and Base Foundations Installation Coupling Misalignment Pulley Belt Tension Adjustment Pipework Commissioning Recommended Lubricants Lubricating the Pump Flushed Seal Arrangements Connecting the Flush Flushing Pipework Layout Flushed Seal Housing Connections Flushing Fluid Flushing Pressure and Flow Rate Page No aftr BRA G3 IN ake Sa a OND OD Contents 6 0 6 1 6 2 6 3 7 0 10 0 10 1 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 9 Start up Shut Down and Cleaning in Place Start up Checklist Pump Shut Down Procedure Direction of Rotation Maintenance and Inspection Maintenance Schedule Recommended Spare Parts Maintenance Tools Rotor Retention Torque Locking Assembly Mounting Instructions Torque Locking Assembly Release Instructions Rotor Retention Torque Locking Assembly General Maintenance Before Dismantling the Pump Removing the Rotors Removing the Rotorcase Replacing the Front Gearcase Seals Fitting and Shimming the Rotorcase Front Cover Reversal Removal of Rear Gearcase Cover and Replacement of Seals Refitting the Rotors Wearplates Gearbox Components Timing Gears Timing Adjustment Timing Gear Removal Lipseal Removal and Fitting Fitting the Timing Gears Shaft Removal Bearings General Bearings Removal Fitting Bearings to the Shaft 10 10 Shaft Repl
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