ALLWEILER~
Operating and Maintenance Instructions with Dismounting and Mounting Instructions
VM no.: 626.0011 GB Edition: 08.95
Screw Pump Twin Aggregates Series ZAS, ZASV
Order no.:
Machine no.:
Operating data of pump as per order data sheet Dimensions as per technical specification VM 533/ ...
Contents
1. General 2. Safety
3. Transportation and Intermediate Storage 4. Description
5. Installation/Mounting 6. Start-up/Shutdown 7. Maintenance/Repair
Ident no.: 550 213
Retain for future use!
Pump ident. no.:
Pump type:
These Operating and Maintenance Instructions contain information from the pump manufacturer. They may need to be supplemented by instructions of the operator company for its personnel.
These instructions do not take account of specific information relating to opera- tion and maintenance of the process plant into which the pump is integrated.
Such information can only be given by the persons responsible for construc- tion and planning of the plant (plant man ufactu re r).
Such specific instructions relating to operation and maintenance of the process plant into which the pump is integrated have priority over the instructions of the pump manufac- turer.
Refer to the operating instructions of the plant manufacturer!
8. Operating Faults, Causes and Remedial Action
9. Associated Documentation
ZAS,ZASV
1 General
1.1 Abbreviation
The abbreviation of the screw pump is set up according to the following schema, and is engraved on the type plate.
Example:
Series
l
ZA S 3150 G 8.3 F E - W20 Twin Aggregate _ _ _ _
---II
ZAS = horizontal installation ZASV
=
vertical installationSize ---~
= Delivery (approx.) in 11th] at p = 4 bar, v = 12 mm2/s and f= 50 Hz
Special design feature - - - ' G = Internal slide bearing
U = Rolling bearing inside, Shaft seal uncooled/unheated Shaft seal
B.3 = Mechanical seal Design with filter Design with electric filter-heating Material code
1.2 Application and installation
The screw pump twin aggregates of series ZAS and ZASV consist of two three-screw rotating displace- ment pumps, in flange construction, for lubricating fluids.
The fluids must contain no abrasive components and must not chemically attack the materials of the twin aggregate.
VM 626.0011 GB/OB.95 -Ident-Nr. 550213 2 1.3
1.4
1.5
1.6
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Performance data
The exact performance data applicable to the pump can be taken from the order data sheet and/or acceptance test report, and are engraved on the name plate.
The pressure data indicated there apply only to approximated static pressure load. In the case of dynamic alternating pressure load, consult the manufacturer.
warranty
Our warranty for shortcomings in the supply is laid down in our delivery conditions. No liability will be undertaken for damages caused by non-compliance with the operating instructions and service conditions.
If at any later date the operating conditions change (e.g.
different fluid conveyed, speed, viscosity, temperature or supply conditions), it must be checked by us from case to case and confirmed, if necessary, that the pump is suited for those purposes. Where no special agreements were made, pumps supplied by us may, during the warranty period, only be opened or varied by us or our authorized contract service workshops;
otherwise our liability for any defects will cease.
Testing
Prior to leaving our factory, all pumps are subjected to a thorough test run and performance test on the test stand. Only properly operating pumps, achieving the performance assured by us, leave the factory.
Thus, compliance with the following operating instructions ensures fault-free operation and full delivery.
The pump aggregates were subjected to a type testing according to DIN 4736. and provided with a registered DIN test mark.
Availability
As a matter of principle, we recommend stocking replacement pumps and withdrawable units (hydraulic action system) where the supplied pumps are a decisive factor in maintaining a production or delivery process. In this way downtimes can be avoided, or reduced to a minimum.
ZAS,ZASV
2 Safety
These operating instructions contain basic safety instructions for installation, operation and maintenance. It is therefore essential that they are read by fitters and all specialist staff and customer personnel prior to installation and start-up. They must always be kept at hand at the place of installation.
The special safety instructions contained in the other chapters must be observed in addition to the general safety instructions in this chapter.
Marking of instructions in the operating instructions
The safety instructions contained in these operating instructions which represent a danger to personnel if not complied with are specially marked by the general danger symbol:
Warning symbol as per DIN 4844-W9
Warning of danger from electric voltage is given as follows:
Warning symbol as per DIN 4844-W8.
Instructions which are essential to avoid endangering the machine and its functioning are marked by the word
I ATTENTION I
Instructions affixed directly to the machine such as
• Directional markers
• Signs for fluid connections
must always be observed and maintained in fully legible condition at all times. .
Personnel qualification and training
The operating, maintenance, inspection and mounting personnel must be appropriately qualified for the duties assigned to them. The scope of their responsibilities, competency and supervisory duties must be closely controlled by the customer. If the personnel do not have the required knowledge, they must be trained and instructed. If r~quired, this may be provided by the manufacturer/supplier on behalf of the customer. The customer must additionally ensure that personnel fully understand the content of the operating instructions.
VM 626.0011 GB/OB.95 -Ident-Nr. 550213 3
2.3
2.4
2.5
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Dangers in the event of non-compliance with safety instructions
Failure to comply with the safety instructions may result in danger to personl>, and place the environment and the machine at risk. Non-compliance with the safety instructions may lead to the loss of any claims for damages.
Non--compliance may relate to the following dangers:
• Failure of important functions of the plant
• Failure of specified methods for maintenance and servicing
• Danger to persons resulting from electrical, mechanical and chemical effects
Danger to the environment resulting from leakage of hazardous substances
Respbnsible working practices
The safety instructions contained in these operating instructions, current national accident prevention regulations, as well as internal working, operating and safety rules of the customer, must be observed.
Safety instructions for the user/operator
• Hot or cold parts representing a danger must be protected against accidental contact on site.
• Protection against accidental contact for moving parts (such as the coupling) must not be removed while the machine is in operation.
• When operating pump aggregates in a dust-laden environment (e.g. milling, chipboard manufacture, bakeries), the surfaces of the pumps and motors must be cleaned at regular intervals, depending on local conditions, in order to maintain the cooling effect and eliminate the possibility of spontaneous combustion. This particularly applies to aggregates in hot-oil plants. Refer also to explosion protection regulations (ZH 1/10).
• Leakage (e.g. from the shaft seal) of hazardous substances being handled, such as explosive, toxic or hot materials, must be discharged such that no danger to persons or the environment is created.
Legal regulations must be observed.
• Dangers from electrical energy must be eliminated.
For details in this regard, refer to VDE and local power company regulations.
ZAS,ZASV
2.6 Safety instructions for maintenance, inspection and mounting work
The operator company shall ensure that all maintenance, inspection and mounting work is performed by authorized and qualified specialist personnel who have thoroughly studied the operating instructions.
Work on the machine is only to be carried out when the machine is at a standstill. The means of shutdown of the machine described in the operating instructions must always be followed.
Pumps or aggregates handling fluids which are detrimental to health must be decontaminated. All safety and protective devices must immediately be refitted and made operational on completion of the work.
The instructions under Section 6.1, "Preparation for start-up", must be observed before restarting.
2.7 Unauthorized conversion and production of replacement parts
Conversion or modification of the machines is only permissible after consultation with the manufacturer.
Original replacement parts and accessories approved by the manufacturer serve safety purposes. If other parts are used the manufacturer cannot be held liable for the consequences.
2.8 Impermissible modes of operation
The operating safety of the machine supplied is only ensured when it is used in accordance with Section 1 of the operating instructions. The limit values given on the data sheet must under no circumstances be exceeded.
VM 626.0011 GB/08.95 -Ident-Nr. 550213 4
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ZAS, ZASV
3 Transportation and Intermediate Storage
3.1 Packaging·
Attention must be paid to the markings on the packaging.
The suction and pressure sides and all auxiliary connections must always be closed with dummy plugs during transportation and storage. The plugs must be removed when the pump aggregate is installed.
3.2 Transportation
The· pump or pump aggrf)gate is to be safely
transported to the place of il1stallation, if required by means of lifting gear.
~
The crane d~vice and cables must be adequately , dimensioned. The cables must not be attached•. only to the attachment eyes of the motor.
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During transportation ensure that theATTENTION
aggregate is secured against toppling over. The attachment eyes of the motor can be used to secure it.VM 626.0011 GB/08.95 -Ident-Nr. 550 213 5
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3.3 Preservation and storage of the screw pumps 3.3.1 Preservation
If required, the pumps delivered by us are already provided with the requested preservation protection according to the storage time specified by the customer.
Also in the case of prolonged shutdown, the pumps must be protected against corrosion. In those cases, an outside and inside preservation is to be provided. The durability of the protection against corrosion, which is limited in time, depends on the composition of the preservative to be applied and the storage conditions.
Therefore, such preservatives should only be used which have a minimum durability of 12 months. The below-listed preservative can be applied for outside and inside preservation.
3.3.1.1 Outside preservation Points of preservation All bright and unvamished parts such as:
shaft ends, couplings, flange facings, valve and manometer connections
Preservative TECTYl506 or mixture of TECTYl 506 and TECTYl511-M
<D
The outside preservative should be applied by painting or spraying with a spray gun.
3.3.1.2 Inside preservation Points of preservation Pump casing inside, screw spindles, ball bearing, pressure-relief valve
Preservative Mixture of TECTYl 506 and TECTYl511-M
<D CD Manufacturer: VAlVOLINE OEl GmbH & Co.
Uberseering 9 22297 Hamburg
Note: The preservative listed above is to be regarded as a recommendation. Preservatives having the same preserving properties offered by other mineral oil producers can also be used.
The preservative is to be applied by filling the pump. For these purposes, the suction side of the pump must first be closed with a dummy flange. During filling, the pressure flange must be on a higher level than the suction flange. During the filling process, the shaft must be slowly cranked against the direction of rotation.
Filling must be continued until the preservative reaches the sealing strip of the delivery flange, bubble-free.
Then the outlet side is to be closed with a dummy flange.
3.3.1.3 Monitoring of preservation
In the event of prolonged storage, the preservation of the pump must be checked by the customer at regular intervals.
Every six months the pump level must be checked; if necessary, preservative must be topped up to the sealing strip on the pressure flange.
At the same time; the packing must be checked for destruction, and repaired if necessary.
Note: Liability for damages caused by improper preservation cannot be assumed by us.
ZAS, ZASV
3.3.1.4 Durability of the preservative
According to the preservative manufacturer, the durability of "TECTYL 506« is 4 to 5 years in case of indoor storage and 12 to 24 months in case of outdoor storage, and that of "TECTYL 511-M« approx. 18 months in case of indoor storage.
When mixing "TECTYL 506« and "TECTYL 511-M«
in the same proportion, a durability of 2 1/2 to 4 years in case of indoor storage, and a maximum of 12 months in case of outdoor storage under roof can be expected.
With additional packing, the service life is increased.
The active ingredients contained in this preservative provide sufficient protection against corrosion even at high air humidity (sea, tropical climate). Therefore, a temperature limitation (+ and -) does not exist.
3.3.1.5 Depreservation
Prior to setting the pump in motion, the preservative applied must be removed.
The preservative applied for inside preservation can normally be removed by flushing the pump with the fluid
~ to be conveyed.
~ Environmentally compatible disposal must be ensured.
In addition, a suitable solvent may be applied for removing the inside and outside preservation.
Appropriate solvents are for example: petroleum, benzene, Diesel fuel, spirit, alkalis (industrial cleaners) or any other wax solvents. Steam jet cleaning devices with appropriate admixtures can also be used (allow wax solvent to act beforehand).
I ATIENTIONI
Prior to start-up af!er prolonged storage,L . . . _ _ _ ....J. an elastomers (O-rings, shaft seals) must be checked for their elasticity of shape. Embrittled elastomers must be exchanged. Elastomers of ethylene-propylene rubber (EPDM) must always be replaced. The pump must be filled with fluid to prevent s.eizing of the components. A pressure-relief valve attached or fitted in the pipeline must be checked for passage.
Note: If on the plant side, the pipelines, (oil) tanks or other parts are wetted with the paraffin-containing preservative, the entire plant must be depreserved as paraffin is detrimental to the air separating capability of the (oil) filling. This may result in unsteady operation of the pump and loud noise.
3.3.2 Storage
During storage of the pump, the suction and outlet branches and all other supply and discharge branches must always be closed with dummy flanges or dummy plugs.
Storage should be in a dry, dust-free room. During storage, the pump should be cranked at least once a month. During this process, parts such as the shaft and bearings should change their position.
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Only proper storage and packing ensuresATIENTION
the durability of the preservative applied.VM 626.0011 GB/OB.95 - Ident-Nr. 550 213 6
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ZAS, ZASV
4 Description
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
Structural design of the pumps
Three-screw pumps in flange design form, with a double-threaded driving spindle and two double-threaded idler spindles, enclosed in a housing insert with narrow running clearance.
The delivery elements are installed in a pump housing which is closed off on the drive side and the end side by pump caps.
Bearing and lubrication
Sizes 150 to 3150: By an internal medium-lubri- cated slide bearing.
Sizes 3600 to 6450: By an internal medium-lubri- cated groove ball bearing to DIN 625.
Shaft seal, design 8.3
Uncooled, maintenance-free mechanical seal of the unbalanced type.
Material design of the mechanical seal:
Rotating seal ring: Tungsten carbide Stationary seal ring: Tungsten carbide Auxiliary gaskets: Viton
Spring: CrNiMo steel
Metal parts: CrNiMo steel
Flanges/connections Flanges
Suction and outlet side with flange connections.
Counter flanges PN16, DIN 2633 with screws and gaskets are included in the scope of supply.
Connestions
lAS without filter: lAS with filter:
M1, M2 Manometer B7 Draining filter casing E7 Venting filter caSing M1, M2, M3 Manometer lASV without Filter: lASV with Filter:
B8 Venting B8 Venting
M1, M2 Manometer E7 Draining filter casing M1, M2, M3 Manometer
Pressure-relief valve
As an overload protection, a pressure relief-valve is in- stalled in each pump which is serially set to a response pressure of 7 bar. .
Filter
To protect against coarse dirt contamination, the pumps can be fitted with a built-on star-shaped strainer filter, mesh width 0.4 mm.
A mano-vacuummeter supplied with the filter indicates the pressure downstream of the filter. This gives an in- dication of the pressure loss in the filter, and so pre- ver:lts possible dirt contamination.
Electric heating
In design versions with filters, heating shells can be used for filter heating.
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4.2
4.3
4.3.1
4.3.2
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Mode of operation of the screw pumps
Through the suction connection and the suction chamber in the reversing valve casing, the fluid is conveyed into the suction chamber of the pump. From there the fluid flows into the spindle chambers, which are constantly formed by the rotary motion at the spindle end on the suction side. By the translatory rotary motion, the chambers filled with the fluid move from the suction side to the outlet side. During this process the closed chamber volume does not change.
At the spindle end on the outlet side the chamber opens towards the delivery chamber. The fluid is steadily pushed out into the delivery chamber from where it is transported, through the delivery chamber of the reversing valve casing and the pressure connection, into the pressure pipeline.
The axial thrust acting on the faces of the profile flanks on the outlet side is hydraulically balanced by an appropriate dimensioning of the compensating piston of the driving spindle. Thus the bearing is relieved of the hydraulic axial thrust. The axial thrust of the two idler spindles is hydrodynamically absorbed by the pump cover, non-drive side or by the filter casing.
The idler spindles are hydraulically driven by means of appropriate dimensioning of the spindles. Only the torque resulting from the fluid friction is transmitted via the profile flanks. They are therefore practically stress-free, and not subject to any wear.
As a result of the constant chamber volume the medium inside the pump is transported, almost entirely free of turbulence and squeezing, from the suction side to the outlet side.
The compartment for the shaft seal is connected to the pump suction chamber.
The structural design and mode of operation of the screw pump ensure a very low noise level and an almost pulsation-free delivery.
Structural design of the twin aggregate
Twin aggregate of the compact type of construction, with two screw pumps connected with one another by means of a reversing valve casing.
Drive
A specific driving motor (serial standard motor) is firmly assigned to each pump size.
Normally, surface-cooled three-phase squirrel cage induction motors are used as driving motors, type 1M V1, class of protection IP 54 to lEG standard, class B insulation, outputs and speeds to DIN 42 677.
The exact motor data are to be found in the technical specification VM 564/ ... or in the order data sheet.
Shaft coupling and contact protection
Power transmission is effected via a flexible coupling.
Additional radial forces must not act on the driving spindle.
I ATIENTIONI
Driv~ b¥ means of belt or gear wheel is not . . admissible.The pump lanterns serve as contact protection as per DIN 24 295.
~
According to accident prevention regulations, the , pump must only be operated with a protection• against accidental contact as per DIN 24 295.
ZAS,ZASV
If no contact protection is provided, it must be attached by the operator.
4.3.3 Pump brackets
The flange pumps are joined to the drive motor by pump brackets (lanterns) as standard.
4.3.4 Non-return valves/stop valves
For each pump, a non-return valve and a stop valve are provided in the reversing valve casing. The non-return valves operate automatically and are lockable by hand.
4.3.5 Operating control device Manometers:
ZAS/ZASV without filter
Outlet side: one manometer (included in the scope of supply). If a mano-vaccummeter is requested on the suction side, same must be provided at the site. Bore hole of the screw plug (227) is provided for con- nection.
ZAS/ZASV with filter
Suction side: two mano-vakuummeters Outlet side: one manometer
(each included in the scope of supply).
Reversing unit:
If a reversing unit was supplied for operation control, its circuitry is such that in case of failure of the operating pump, the spare pump is automatically switched on.
Signal lamps denote the respective operating condi- tions.
Reversing unit UZ1: For motor performance up to 3kW (380V) across-the-line starting.
For the scope of supply of the reversing unit, refer to our Brochure VM 564/ ...
4.3.6 Oil through
4.4
ZAS: with loose oil through.
ZASV: with firmly attached oil through.
Mode of operation of the screw pump twin aggre- gate
Both screw pumps are jointly attached to the reversing valve casing (301). While one pump is in operation, the spare pump is at standstill.
The pumps can be actuated alternately by hand or automatically by means of a reversing unit (UZ1). By means of two separate connecting chambers in the re- versing valve casing (301), the respective two suction flanges and the two pressure flanges of the two pumps are connected with one another. Uninterrupted delivery during the reversing process is thus ensured.
During operation, the two lockable non-return valves (356) and the two stop valves (355) must be opened so that reversal is optionally possible from one pump to the other. The respective connected pump draws the fluid through the suction chamber of the reversing valve casing (301).
The operating pressure built up in the delivery chamber of the pump opens the non-return valve (356) of the op- erating pump and, through the pressure in the delivery chamber of the reversing valve casing (301), closes the non-return valve (356) of the non-operating pump.
This prevents the spare pump from running in reverse motion.
VM 626.0011 GB/OB.95 -Ident-Nr. 550 213 8
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Switching diagram
Series ZAS/ZASV without filter
1 0 - 0 - 0
o_o~ 70
0
5r. 0 or-
5 1I l~Lo o· oj
.C?, ~i
3
Lo_o~o-~o~
L.J
1 Operating and spare pump 2 Three-phase motor (901) 3 Stop valve (355)
5 Lockable non-return valve (356)
7 Manometer with ball valve (360) and (363) Switching diagram
Series ZAS/ZASV with filter
o
_ 0 - 7 0 l
0
1
5 0I
1 Operating and spare pump 2 Three-phase motor (901) 3 Stop valve (355) 4 Filter (481)
o_-o--oJ
5 Lockable non-return valve (356)
6 Mano-vacuummeter with ball valve (361) and (362) 7 Manometer with ball valve (360) and (363)
ZAS, ZASV
5 Installation/Mounting
5.1 Installation
lAS aggregates can be installed horizontally or verti- cally.
lASV aggregates must be installed vertically.
It'
F=or safety reasons the "downward-facing motor"~
arrangement is not permitted.5.2 Mode of fastening
The mode of. fastening is dependent on the local installation conditions.
lAS aggregates are fastened by means of foot angles at the place of installation.
For lAS V aggregates, the fixed oil sump serves as the fastening base.
Precise details on form and dimensions are given in the installation diagram.
5.3 Foundation 5.3.1 Design
The foundation may be concrete or a load-bearing foundation frame, of steel for example.
The condition for all foundation designs is:
The foundation must be designed so that it can take the weight of the pump aggregate across its entire area.
5.3.2 Characteristics of a steel foundation frame A steel foundation frame must be designed so that the foot angle or the oil trough can be bolted or welded on.
5.3.3 Characteristics of a concrete foundation
The set concrete foundation must be horizontal, flat and clean. Smears on the foundation must be removed.
The cut-out anchoring holes for the foundation bolts must be cleaned and blown out with air.
5.4 Checking the coupling alignment
In the case of pumps with flanged drive motor, the pump and motor are precisely centered in the lantern.
Alignment Or· re-alignment of the coupling is not required.
Note: Improper handling, e.g. during transportation, may impair the alignment between the pump and the motor. In this case the motor must be rem'oved from the lantern. The true running accuracy and axial run-out of the shaft ends to the center diameters and end faces of the lantern must be determined by means of a dial gauge with retaining bracket and clamp. If a value of more than 0.05 mm is recorded, the pump and/or the motor must be returned to the factory for checking.
5.5 Assembly of pump and drive motor
If the aggregate is only assembled at the place of use, the coupling is assembled as follows:
1. Coat the pump and motor shaft ends with a fine film of molybdenum disulfide (e.g. Molykote) and insert keys.
VM 626.0011 GB/OB.95 -Ident-Nr. 550 213 9
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2. Push on the coupling halves on the pump and motor side with the aid of a pusher device until the shaft end is flush to the coupling hub.
I ATTENTION I
The possibility o~ axial shock stress onL . _ _ _ _ • the pump and drive motor components during assembly of the coupling must be eliminated.
3. The coupling does not need to be re-aligned.
4. Flange the pumps and motors onto the lanterns.
5.6 Space required for maintenance and repair
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The pump aggregate must be accessibleATTENTION
from all sides in order to be able to carry out necessary visual inspections.Adequate space must be provided for maintenance and repair work, in particular for removal of the drive motors or of the complete pump aggregate. It must also be ensured that all pipelines can be attached and removed without hindrance.
5.7 Laying the pipelines 5.7.1 Nominal widths
If possible, the nominal widths of the suction and pressure pipelines should be rated so that the rate of flow does not exceed a maximum of 1 m/s in the suction pipeline and 3 m/s in the pressure pipeline.
Note: The nominal width of the inlet and delivery pipe- line should be the same or greater than the nominal pump width. On the suction side, the nominal width must never be less than the nominal pump width, as otherwise difficulties will be encountered during suc- tion.
5.7.2 Change of cross-sections and directions
Sudden changes of cross-sections and directions, as well as hairpin bends, are to be avoided.
5.7.3 Supports and flange connections
The pipelines must be connected to the pump with the power disconnected. They must be supported close to the pump and must allow easy screwing-on to avoid twisting. When the connections are loosened the pipeline must neither be slanted nor springing, nor must it be under pressure.
Any thermal stresses occurring on the pipelines must be kept away from the pump by suitable means, e.g.
installing compensators.
5.7.4 Cleaning pipelines prior to attachment
Prior to assembly, all pipeline parts and valves must be thoroughly cleaned; especially in the case of welded pipelines, burrs and welding beads must be removed.
Flange pac kings must not protrude inwards.
Water residues, still in the pipeline network from pressing-out or steeping for example, must be removed.
Delivery of water destroys the pump. The pump relies on the fluid being conveyed for its lubrication.
5.7.5 Non-return valves/stop valves
In the reversing valve casing, a non-return valve and a stop valve are provided for each pump.
Note: When the non-return valve and stop valve of the stopped pump are closed the associated filter can be cleaned, even if the pump is under inlet pressure.
ZAS, ZASV
5.7.6 Pressure-relief valve See Section 4.1 ...
5.7.7 Bleeding
The pumps can be bled on the suction side by means of the screw plugs (227) on the pump casing (1). In addi- tion, a vent valve must be provided at the highest point in the pressure pipeline.
Note: In the case of horizontal pump installation and where the connecting flanges are turned to the side, the filling and vent holes and the connections for the pres- sure gauges must point upwards.
5.7.8 Filtering
To protect the pump against coarse dirt contamination, we recommend as a matter of principle installing a filter in the suction pipeline, mesh width 0.4 mm.
Note: The service life of the pump is decisively influenced by the degree of dirt contamination of the fluid being conveyed, that is, by the number, size and hardness of the abrasive components.
5.8 Safety and control devices 5.8.1 Manometers
Dependent on the plant-side operating states, ap- propriate suction and delivery side pressure gauges must be provided. There are connection facilities in the suction and delivery flange of the pump casing. See brochure VM 5641. ..
Standard delivery:
Design without filter: One manometer on the delivery side, measuring point M2.
Note: If, in the version without filter, a mano-vacuum- meter is required on the suction side, it must be pro- vided by the customer. Measuring point M1 is provided for connection.
Design with filter: One manometer on the delivery side, measuring point M2. Two mano-vacuummeters on the suction side on the filter, measuring point M3, for mea- surement of the pressure downstream of the filter. This can be used to prevent filter contamination.
Note: Ball cocks in front of measuring instruments may only be opened to monitor pressure.
5.8.2 Pressure-relief valve and other safety and control devices
A pressure-relief valve is installed in each pump (see Section 4.1.4).
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Other safety and control devices, as re-ATTENTION
qui red for oil supply installations in accor- dance with DIN 4736, are not supplied with the pump aggregate as standard. They can be acquired from us as accessories, but must in all cases be installed by the operator.5.9 Electrical connections
The power cables of the coupled drive motors, any
~ fitted filter heating and/or switchgear must be con-
~ nected by a qualified electrician. The applicable VDE specifications and the regulations of the local power supply company must be observed.
Avoid all danger from electrical energy.
VM 626.0011 GB/08.95 -Ident-Nr. 550 213 10
5.9.1
5.9.2
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Motor connection
Standard three-phase motors can be used for the fol- lowing circuit configurations:
Terminal connection diagram:
~::::;:;::::~
OO$)U2
~V2
Ll l2 L3 l1 L2 l3
D.-circuit Y-circuit
Electric filter heating
The heating shells of the electric filter heating system should be connected to a voltage of 220 V according to the following diagram.
Connection diagram
,"-'-' . ,
.I I
w..R-+-_ _ _
~2~20V....
Mp
Degree of protection IP 44
ZAS, ZASV
6 Start-up/Shutdown
6.1 Preparation for start-up 6.1.1 Filling the pumps with fluid
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Prior to initial operation, the two pumpsAITENTION must be filled with fluid and bled. This at the same time provides the spindles with the sealing required for suction.
The pump must not run dry.
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Before filling, the operator must ensureAITENTION careful and thorough rinsing of the pump if the fluid to be conveyed is not chemically compatible with the test medium (see performance test report).
The fluid should be introduced via the delivery pipeline or the connections on the pump or filter casing, until it emerges free of air bubbles.
~
During bleeding of the pump and the plant, hazardous , or environmentally harmful fluid and gas emerging• must be safely collected and discharged.
6.1.2 Heating the delivery fluid
When conveying heavy heating oils or other delivery media which solidify when cooled, heating must be pro- vided in the plant (e.g. pipe steam trace).
The delivery fluid must be flowable and pumpable when the pump is started up, in order to prevent damage to the pump.
Heavy heating oil, for example, must be heated to at least 100 C above the solidification point before starting the pump.
The pumps can be fitted with built-on filters. Heating shells are used for filter heating (on customer request).
The heating power of the shells should be rated such that, at an initial temperature of 20°C a minimum heat-up time of 120 minutes is necessary. A corre- spondingly longer heat-up time should be expected at lower temperatures (below O°C). The heating system is not suitable for attaining a significant temperature in- crease of the delivery medium during operation. The heating shells should be connected to 220 V (parallel circuit, no in-series connection).
6.1.3 Control of drive motor direction of rotation The direction of rotation of the motor must match the direction of rotation arrow on the pump. The motor can be briefly switched on with the suction and pressure valves open to check the direction of rotation. If the direction of rotation is wrong there is no pump suction.
This damages the pump. The direction of rotation of the three-phase motor can be reversed by swapping any two phases.
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lf the direction of rotation is to be checkedAITENTION before the pump is filled with fluid, the drive motor must be disconnected from the pump. The pump must not run dry.
VM 626.0011 G8/0B.95 -Jdent-Nr. 550 213 11
6.2 Start-up 6.2.1 Starting
ALLWEILER~
1. Prior to starting the operating pump, the two stop valves on the suction side and the two lockable non- return valves on the outlet side of the reveresing valve casing, and gate valves, if any, must be opened in the plant.
2. The pumps are fitted with a pressure-relief valve, which is set as standard to a response pressure of 7 bar.
The opening pressure can be changed within nar- row limits using an adjusting screw. The pressure- relief valve must not be used to regulate the flow.
3. During starting, a vent valve installed on the outlet side of the plant must be opened until the air has escaped from the suction side of the pump. As soon as fluid emerges the vent valve can be closed. The pump is self-priming and is automatically vented without counter-pressure.
6.2.2 Drive
Switch on the motor.
Pay attention to product-specific characteristics. Refer to the operating instructions of the drive motor manufacturer.
6.2.3 Checking the delivery values
When the motor has reached its operating speed, the inlet pressure and outlet pressure of the pump must be checked using manometers.
The motor must not be overloaded. The current consumption can be checked with an ammeter. In this connection, the temperature and viscosity of the fluid must also be checked. The readings must be checked against the layout or acceptance test report.
Note: Pressure gauges are normally equipped with stop valves. The stop valves may be openend only dur- ing start-up for pressure control purposes. During per- manent operation. same must be kept closed.
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AITENTIONI
~f there should b~ an inadmissible increa~eL . . . . ___- ' . In pressure, Internal pressure-relief
valves may shift the media from the discharge to the in- take side (recirculation).
Recirculation leads to heating up of the medium. An in- admissible pressure and temperature increase can be indicated by a pressure gauge and a thermometer. De- termine the cause immediately and eliminate it in order to avoid damage to the pump as the result of excessive heating up and the related drop in viscosity.
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6.3 Shutdown
6.3.1 Stopping and interrupting operation
1. Switch off the motor of the operating pump. Make sure the pump runs down smoothly and evenly.
2. The non-return valves and stop valves in the reversing valve casing remain open.
6.3.2 Measures in case of prolonged interruption If a prolonged interruption is intended, the pump must be drained thoroughly via the connections on the pump or filter casing.
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ATTENTION
Ilf the adjusti~g screw. (333) of the built-~n .'--_ _ ----'. pressure-rehef valve IS to be used to drain the pump, the reach of the screw should be recorded beforehand using a depth gauge. The screw must be screwed back in precisely to this depth, so that the re- sponse pressure of the pressure-relief valve is notch~nged.
~ Safe draining and environmentally compatible disposal
Lll
of the fluid must be ensured.Preservative should then be applied to the pump (see Section 3.3).
VM 626.0011 GB/08.95 -Ident-Nr. 550 213 12
ALLWEILER~
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7 Maintenance/Repair
7.1 Maintenance
The instructions in Section 2, Safety, must be observed in maintenance and repair work.
• Regular monitoring and maintenance of the pump and drive motor increases their service life.
The following instructions are generally applicable.
7.1.1 General monitoring
1. The pumps must not run dry.
2. The drive motors must not be overloaded.
3. The suction and pressure pipelines must be checked for leaks. Air must be prevented from entering the delivery system.
4. There must be no serious leakage from the mechanical seals.
5. Pressure and temperature monitors must be observed.
7.1.2 Maintenance of components 7.1.2.1 Bearing and lubrication
Sizes 150 to 3150
In the case of sizes 150 to 3150, the bearing of the driv- ing spindle is provided by a maintenance-free me- dium-lubricated slide bearing.
The service life of the slide bearing is designed to match the service life of the pump under normal operat- ing conditions, and is dependent on the degree of dirt contamination of the delivery medium.
Sizes 3600 to 6450
In the case of sizes 3600 to 6450, the bearing of the driving spindle is provided by a maintenance-free me- dium-lubricated groove ball bearing.
The groove ball bearing of the screw pumps is de- signed for a service life of approx. 24,000 hours under normal operating conditions.
The actual service life may be reduced due to intermittent operation, high temperature, low viscosity, poorly lubricating fluids and the like. We therefore recommend checking the running noises and temperature in the bearing area at regular intervals.
If scraping or rattling noises are heard compared to the normal humming, or if excessive temperature rises are detected, this indicates impending bearing damage, and the groove ball bearing should be replaced as soon as possible (see Dismounting and Mounting Instructions, Section 7.2).
7.1.2.2 Shaft seal, design 8.3
The built-in shaft seal is maintenance-free. Minimal dripping of non-volatile media, such as oils, resulting from the functioning of the components is to be expected. In the event of heavy leakage due to wear, the mechanical seal should be replaced.
VM 626.0011 G8/0B.95 - Ident-Nr. 550213 13
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Since the mechanical seal must not beAnENTION allowed to run dry, the pump must only be started up when charged and bled.
For dismounting and mounting of the shaft seal, see Dismounting and Mounting Instructions, Section 7.2.
7.1.2.3 Pressure-relief valve
Pressure-relief valves must be checked from time to time, in particular after prolonged downtimes, for passage and functioning. Leaking pressure-relief valves may cause damage to the pump. Damaged parts should be replaced or repaired as necessary.
Note: Operating instructions for pressure-relief valves should be ordered separately.
The pressure-relief valves are set as standard ex works to an opening pressure of 7 bar. If the opening pressure is to be changed, the screw plug (222) in the end-side pump cover (4) or in the filter casing (9) must first be removed. The adjusting screw (333) is then ac- cessible.
Turning the screw clockwise increases the opening pressure, turning anti-clockwise reduces it. Any ad- justment must be made only with an intact pressure gauge.
7.1.2.4 Filter
The filters fitted to screw pumps must be cleaned at regular intervals.
The filter casings (9) are fitted with a mano-vacuum- meter (361) which indicates the pressure downstream of the filter (481). The pressure loss gives an indication of the degree of dirt contamination of the filters. For pre- cise recording of the differential pressure, we recom- mend installing a pressure gauge upstream of the filter on the suction flange of the pumps, or in the suction pipeline. In the event of a detectable differential pres- sure, the filter (481) must be cleaned, or replaced as necessary.
Filter cleaning
Filter cleaning involves removing the filter (481) from the filter casing (9), cleaning it and rinsing out the dirt particles encrusted on the filter casing bottom.
• Stop the operating pump and switch to the standby pump.
• Close the non-return valve and stop valve of the stopped pump.
• Allow the pump and delivery fluid to cool to ambient temperature.
• After loosening the hexagon screws (207), remove the (filter) casing cover (7) and take the filter (481) from the filter casing (9).
• Drain the filter casing (9) by way of the screw plug (235).
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Note: Use a collecting tank.
Hazardous substances and/or environmentally harmful media must be drained off and collected such that no danger to life and limb is created. Envi- ronmentally compatible disposal must be ensured.
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• Place the filter in a vessel containing cleaning fluid to clean it and remove encrusted matter.
Health-endangering cleaning agents must only be used in compliance with DIN safety data sheets.
Note: The filter must only be immersed in the fluid up to the rim, as otherwise the loosened dirt will attach to the clean side.
• After allowing the filter to drip off from the clean side to the dirty side (from the inner to the outer, not vice versa!), blow it out with compressed air.
Note: Suitable cleaning agents are benzene, spirit, diesel fuel or a solvent-free cold cleaning agent.
The use of other special cleaning agents is possible.
The concentration depends on the nature and se- verity of the dirt.
A soft brush can be used to clean the filter. Sharp im- plements must not be used.
In the case of excessive dirt contamination we rec- ommend replacing the filter (481).
• After cleaning, the filter (481) is loosely slotted onto the pipe (30) in the filter casing bottom. The filter cover (7) is re-attached to the filter casing (9).
Note: The O-ring (119) must be in its groove and must not be damaged. Replace it as necessary. The (filter) casing cover (7) must close air-tight, to pre- vent the pump from taking in air.
• Re-open the non-return valve and stop valve of the stopped pump. Fill and bleed the pump as per Sec- tion 6.
Note: When retrofitting a filter to a pump, it is essential that the pipe (29) is installed first.
7.1.2.5 Coupling
The
condition of the flexible elements in the coupling should be checked after initial start-up and at regular intervals.Note: Worn flexible elements must be replaced.
7.1 .2.6 Drive
Refer to the operating instructions of the motor manufacturer.
VM 626.0011 G8/0B.95 -Ident-Nr. 550213 14
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7.2 Repair (Dismounting and Mounting Instructions) General
Trained Service fitters are available on request to carry out mounting and repair work.
Where repairs are carried out by the operator's own
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personnel or by specialist fitters, it must be ensured that~ the pump is fully drained and cleaned.
This particularly applies to pumps which are sent for repair to our factory or one of our service workshops.
We must refuse acceptance of repair work on pumps filled with fluid, for the protection of our staff and for environmental reasons. Otherwise we must invoice the customer/operator for the costs of environmentally compatible disposal.
Where repairs are to be carried out on pumps which have been operated with hazardous substances CD and/or environmentally harmful media, the customer/operator must inform its own personnel on site, or our personnel where repairs are returned to our factory or a service workshop, without being specifically requested to do so.
In such cases a verification of delivery material, for example in the form of a DIN safety data sheet, must be submitted to us together with the request for a Service fitter.
Alternatively, you can request a certificate of safety (form no. 448/191) from our Service department, filling it out truthfully, correctly and in full. Send the completed form to the center commissioned with carrying out the repair, or hand it to our Service fitter.
CD Hazardous substances are:
• Toxic substances
• Health-endangering substances
• Corrosive substances
• Irritants
• Explosive substances
• Fire-inducing substances
• Highly flammable, easily flammable and normally flammable substances
• Carcinogenic substances
• Substances impairing fertility
• Genetically distorting substances
• Substances in other ways hazardous to humans
For all work on site, the operator's own personnel
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and/or our fitters must be advised of the possible~ dangers involved in the repair work.
The most important dismounting and mounting operations are described in these instructions. The mounting steps described in the individual sections must be consistently observed.
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7.2.1 Dismounting the screw pump
Before dismounting, the following work must be carried out:
• Switch on the standby pump and stop the operating pump. Close the non-return valve and stop valve of the pump to be dismounted. Service is maintained by the standby pump.
Make sure the power cable is disconnected from the pump motor by a qualified electrician. Electrical danger must be eliminated! The motor must be se- cured against being switched on.
• Drain the fluid in flowable condition from the pump.
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Note: Use a collecting tank.
Hazardous substances and/or environmentally harmful media must be drained off and collected such that no danger to life and limb is created.
Environmentally compatible disposal must be ensured.
• The pump must be depressurized and drained.
• Allow the pump and motor to cool to ambient temperature.
• Remove the manometer cables, manometers and retaining brackets.
7.2.1.1 Dismounting a screw pump from the twin aggregate
• Unscrew socket-head cap screws (215) from lan- tern (460).
• Unscrew hexagon nuts (236) and (238) from suction and delivery flange. Remove socket-head cap screws (206) and (208).
• Detach pump from centering ring of lantern (460) and remove from reversing valve casing (301).
• Remove gasket (125) and (126) and clean sealing faces.
7.2.1.2 Dismounting the mechanical seal from sizes 150 to 3150
• Detach pump-side coupling half from shaft end (12).
Use puller device!
• Remove key (290) from driving spindle (12).
• Unscrew socket-head cap screws (200) from drive- side pump cover (3).
• Remove drive-side pump cover (3) with mechanical seal counter-ring from pump casing (1) over driving spindle (12).
• Remove O-rings (120) and (122) and clean sealing
•
faces.
• Remove circlip (250) from drive-side pump cover (3).
VM 626.0011 GB/OB.95 -Ident-Nr. 550 213 15
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• Use an implement to dismount mechanical seal counter-ring (186) and O-ring from pump cover (3).
Note: Special care should be taken to ensure that the mechanical seal counter-ring is pushed out con- centrically over the shaft and not canted, to avoid damaging the counter-ring.
• Remove rotating part of mechanical seal (186) over driving spindle (12).
• Remove support washer (263) from driving spindle (12).
7.2.1.3 Dismounting the spindle set, slide bearing and casing insert from siies 150 to 3150
• After removing shaft seal, detach spindle set with bearing ring (10) from casing insert (2).
• Dismount idler spindles (13) from driving spindle (12).
• Remove bearing ring (10) from driving spindle (12).
• Unscrew socket-head cap screws (201) from end- side pump cover (4) or filter casing (9).
• Remove end-side pump cover (4) or filter cover (9) from pump casing (1).
• Remove gasket (100) and cleaning sealing faces.
• Unscrew socket-head cap screw (24) from side of pump casing (1).
Note: This socket-head cap screw fixes the casing insert (2) in position.
• Mark positions of casing insert (2) and pump casing (1) to each other.
• Press casing insert (2) out of pump casing (1) from pump-end side using a suitable tool. In case of pumps with filter, first remove pipe (29) from pump casing (1).
7.2.1.4 Dismounting the mechanical seal and spindle set from sizes 3600 to 6450
• Detach pump-side coupling half from shaft end (12).
Use puller device!
• Remove key (290) from driving spindle (12).
• Unscrew socket-head cap screws (200) from drive- side pump cover (3).
• Remove O-rings (120) and (122) and clean sealing faces.
• Remove drive-side pump cover (3) with spindle set, mechanical seal (186) and groove ball bearing from pump casing (1) .
• Dismount idler spindles (13) from driving spindle (12).
• Remove circlip (250) from drive-sidtl pump cover (3).
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• Press driving spindle (12) with groove ball bearing (292), support washer (263), spacer bush (20) and mechanical seal (186) out of drive-side pump cover (3) using a suitable tool.
• Remove mechanical seal (186) from driving spindle (12).
• Unscrew socket-head cap screws (201) from end- side pump cover (4) or filter casing (9).
• Remove end-side pump cover (4) or filter cover (9) from pump casing (1).
• Remove gasket (100) and cleaning sealing faces.
• Unscrew socket-head cap screw (24) from side of pump casing (1).
Note: This socket-head cap screw fixes the casing insert (2) in position.
• Mark positions of casing insert (2) and pump casing (1) to each other.
• Press casing insert (2) out of pump casing (1) from pump-end side using a suitable tool. In case of pumps with filter, first remove pipe (29) from pump casing (1).
7.2.1.5 Dismounting the groove ball bearing from sizes 3600 to 6450
• After removing shaft seal and spindle set, dismount spacer bush (20) and circlip (251) from driving spindle (12).
• Detach groove ball bearing (292) from driving spindle (12). Use puller device!
• Clean bearing seats.
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7.2.2 Mounting the screw pump
I
ATTENTIONI
Before remounting check all p~rts fo~ ~earL . . . . __- - - - ' . and, as necessary, replace with onglnal replacement parts.
Clean all parts before mounting. Always fit new gaskets.
7.2.2.1 Mounting the casing insert, slide bearing and spindle set to sizes 150 to 3150
• Lightly oil the fitting faces on the casing insert (2).
Press casing insert (2) into pump casing (1) from drive side using a suitable tool.
Note: Pay attention to marking made prior to dis- mounting!
• Drill together pump casing (1) with casing insert (2) by way of bore hole on side for socket-head cap screw (24).
Bore diameter: 4 mm Bore depth: 6 mm
• Screw socket-head cap screw (24) with sealing washer (151) into side of pump casing (1) and tigh- ten.
• Push bearing ring (10) over driving spindle (12) up to collar.
• Lightly oil driving spindle (12) and press into pump casing (1) from drive side together with bearing ring (10).
Note: This guides the driving spindle concentrically through the bearing ring in the pump casing.
• Insert new joint tape (165) between bearing ring (10) and pump casing (1).
Note: Light oiling makes insertion easier.
• Screw idler spindles (13) into casing insert (2) from pump-end side.
• In case of pumps with filter, push pipe (29) over cas- ing insert (2).
• Place new gasket (100) on cleaned sealing face of pump casing (1).
• Attach end-side pump cover (4) or filter casing (9) to pump casing (1) with socket-head cap screws (201 ).
7.2.2.2 Mounting the mechanical seal to sizes 150 to 3150 Mechanical seals are high-grade precision parts.
Careful handling and extreme cleanliness during instal- lation are essential to ensure proper functioning. A suit- able lubricant can be used to aid mounting (e.g. oil, not grease).
• Push support washer (263) over driving spindle (12).
• Push rotating part of mechanical seal (186) over driving spindle (12) up to support washer (263).
• Push mechanical seal counter-ring (186) with new O-ring concentrically into cleaned pump cover (3).
Use a suitable implement.
Note: Special care should be taken to ensure that the mechanical seal counter-ring is pressed con-
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centrically into the pump cover and not canted, to avoid damaging the counter-ring.
• Insert new O-ring (122) into pump casing (1) in front of return bore hole.
• Attach pump cover (3) with new O-ring (120) and built-in mechanical seal counter-ring (186) to pump casing (1) with socket-head cap screws (200).
Note: This presses the sealing tape (165) into its fi- nal position.
• Insert circlip (250) into drive-side pump cover (3).
• Insert key (290) into driving spindle (12).
• Push pump-side coupling half onto driving spindle (12).
7.2.2.3 Mounting the groove ball bearing to sizes 3600 to 6450
• As necessary, carefully clean groove ball bearing (292) with diesel fuel. If the running surfaces are bright and undamaged, the groove ball bearing (292) can be re-used. If not, the bearing must be re- placed.
• Lightly oil bearing seat on driving spindle (12).
• By light tapping on the inner ring, push the groove ball bearing (292) onto the driving spindle (12) up to the shaft shoulder using a suitably sized tube.
• Mount circlip (251) in shaft groove provided in front of groove ball bearing (292).
• Lightly oil driving spindle (12) and press into pump cover (3) together with groove ball bearing (292).
7.2.2.4 Mounting the casing insert, spindle set and me- chanical seal to sizes 3600 to 6450
• Lightly oil the fitting faces on the casing insert (2).
Press casing insert (2) into pump casing (1) from drive side using a suitable tool.
Note: Pay attention to marking made prior to dis- mounting!
• Drill together pump casing (1) with casing insert (2) by way of bore hole on side for socket-head cap screw (24).
Bore diameter: 4 mm Bore depth: 6 mm
• Screw socket-head cap screw (24) with sealing washer (151) into side of pump casing (1) and tigh- ten.
Note: Mechanical seals are high-grade precision parts. Careful handling and extreme cleanliness during installation are essential to ensure proper functioning.
A suitable lubricant can be used to aid mounting (e.g.
oil, not grease).
• Push rotating part of mechanical seal (186) over driving spindle (12) in front of circlip (251).
VM 626.0011 GBlOS.95 -Ident-Nr. 550 213 17
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• Push spacer bush (20) over driving spindle (12) into cleaned pump cover (3).
• Push mechanical seal counter-ring (1·86) with new O-ring concentrically into cleaned pump cover (3).
Use a suitable implement.
Note: Special care should be taken to ensure that the mechanical seal counter-ring is pressed con- centrically into the pump cover and not canted, to avoid damaging the counter-ring.
• Mount circlip (250) in front of mechanical seal count- er-ring (186) in drive-side pump cover (3).
• Insert new O-ring (122) into pump casing (1) in front of return bore hole.
• Push pump cover (3) with new O-ring (120), pressed-in driving spindle (12) and built-in me- chanical seal counter-ring (186) into pump casing (1) and attach with socket-head cap screws (200).
• Screw idler spindles (13) into casing insert (2) from pump-end side.
• . In case of pumps with filter, push pipe (29) over cas- ing insert (2).
• Place new gasket (100) on cleaned sealing face of pump casing (1).
• Attach end-side pump cover (4) or filter casing (9) to pump casing (1) with socket-head cap screws (201).
• Insert key (290) into driving spindle (12).
• Push pump-side coupling half onto driving spindle (12).
7.2.2.5 Mounting a screw pump onto the twin aggregate
• Place gasket (125) on delivery flange and gasket (126) on suction flange.
Note: To facilitate mounting we recommend coating the gasket with a suitable adhesive.
• Push pump into centering ring of lantern (460).
• Attach pump to reversing valve casing (301) with socket-hea.d cap screws (206) and (208) and hexa- gon nuts (236) and (238).
• Attach pump to lantern (460) with socket-head cap screws (215).
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When the screw pump has been mounted the following work must be carried out:
• Attach manometer lines, manometers and brackets to pump.
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The power supply cable must be connected to the motor by an authorized electrician. Electrical danger must be eliminated! Pay attention to direction of rotation.• Fill pump with fluid.
Start up pump as per instructions in Section 6.
7.3 Replacement parts/spare parts
1he parts marked with footnote <D in the parts list can be provided as replacemenVspare parts.
The casing insert (2) with spindles (12) and (13) are available only as a complete spare part set.
However, for operational safety reasons, we recom- mend you always stock a complete cartridge-unit or standby pump.
The advantage is that in the event of a fault or damage the standby unit can replace the non-functioning unit quickly and without great effort.
When ordering spare and replacement parts, besides the part number, denomination and quantity, the fol- lowing should also be quoted:
Pump abbreviation, Pump number, Year of construction.
This information is engraved on the rating plate of the pump.
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8 Operating Faults, Causes and Remedial Action
8.1 Faults with reference number for cause and remedial action
The table below is intended as a guide to identifying faults and their possible causes. Faults relating to the pressure-relief valve are listed separately.
If faults occur which are not listed here, or which cannot be traced back to the listed causes, we recommend consulting the factory, or one of our branch offices or sales offices.
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The pump must be depressurized and drained when faults are being rectified.Screw pump faults Reference numbers for cause and remedial action
No pump suction and no delivery 1, 2, 3, 4, 5, 11
Delivery too low 2,6,7,8,9,10,11
Pump operates noisily 4,5,6,7,8,10,11,12,13
Irregular delivery 6,7, 10
Pump gets too warm 6,7,11,14,16
Pump is seized 14,15,16
Motor overload 6,13,14,15,16
Pressure-relief valve faults Reference numbers for cause and remedial action
Delivery pressure drops 17
Pressure-relief valve does not open 18
Pressure-relief valve does not close 19
Pressure-relief valve knocks 20
8.2 Causes and remedial action
Ref. no.: Cause Remedial action
1 Pump not filled with fluid before initial operation. Fill purnp with fluid.
2 Stop valves/sliders not open or only partially Fully open stop valves/sliders during operation.
open.
3 Motor direction of rotation wrong. The direction of rotation of the motor must match the direction of rotation arrow on the pump. The direction of rotation can be reversed by swapping any two phases.
4 Suction pipeline or shaft seal leaky. Retighten flange screw connections. Check shaft seal.
5 Air in suction and pressure system. Open vent valve on pump pressure side until air has escaped.
Close valve again.
6 Wrong fluid viscosity. Check that viscosity matches entries in acceptance test report. In case of zero-pressure delivery of low-viscosity fluids, apply 1 to 2 bar to pump.
7 Pressure-relief valve leaking. Check pressure-relief valve for passage. If necessary, regrind valve seat and/or exchange valve cone.
8 Geodetic suction head too high. Check underpressure on suction side using connected pressure/vacuum gauge. Increase fluid level in tank, lower pump.
9 Motor speed too low. Check speed and current consumption of motor. Check voltage and frequency against motor rating plate.
10 Air separating time in operating tank too short. Provide better air separation in operating tank. Return lines must emerge below oil level of tank.
11 Fluid level in tank too low. Fill tank to necessary fluid level.
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12 Flow rate in suction and pressure pipelines too Flow rate in suction pipeline must not exceed max. 1 mis, and
high. in pressure pipeline max. 3 rnIs.
13 Motor speed too high. Check speed and current consumption. Check voltage and frequency against motor rating plate.
14 Delivery pressure too high. Set specified delivery pressure via pressure-relief valve. Pump outlet pressure must not be exceeded.
15 Foreign bodies in pump. Dismantle pump, remove foreign bodies and smooth damaged.
points with oilstone.
Check suction filter and strainer.
16 Damaged ball bearing. Replace ball bearing.
17 Pressure spring fatigued. Install new pressure spring.
Valve seat leaking. Install new valve cone.
18 Pressure spring heavily pre-tensioned. Release pressure spring using adjusting screw, and reset to required pressure.
Valve cone stuck in valve housing.
a) Due to foreign body or Dismantle pressure-relief valve. Clean internal parts.
b) Operating temperature of plant substantially Consult factory.
higher than quoted on order.
19 Pressure spring not pre-tensioned, or Turn adjusting screw to right until required operating pressure insufficiently pre-tensioned. is reached.
Valve seat leaking. Rework or replace valve cone and valve housing.
20 Pressure-relief valve knocking. Check overpressure with pressure valve closed. Reset valve.
Opening pressure 10 % above operating pressure.
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