Series S Stainless Steel Positive Displacement Rotary Lobe Pumps Operating Manual M/101/0211
EC Declaration of Incorporation The designating company Alfa Laval Company Name Birch Road, Eastbourne, East Sussex BN23 6 PQ Address Phone: (01323) 412555 Fax: (01323) 412515 Phone and Fax No. We hereby declare that the following machinery is intended for installation into a machine or to be assembled with other machines into a machine.
EC Declaration of Conformity The designating company Alfa Laval Company Name Birch Road, Eastbourne, East Sussex BN23 6 PQ Address Phone: (01323) 412555 Fax: (01323) 412515 Phone and Fax No. We hereby declare that the following machinery conforms to the machinery directive 89/392/EEC as amended by 91/368/EEC, 93/44/EEC and 93/68/EEC and to the following other relevant directives.
Table of contents The information contained herein is correct at the time of issue but may be subject to change without prior notice. 1. General description ............................................................................. 8 1.1 General description ........................................................................ 8 2. Safety .................................................................................................... 9 2.1 Important information ...................................
1. General description 1.1 General description The Series S pump supplied is a positive displacement rotary lobe pump; it may be supplied with or without a drive unit (see drawing). The drawing shown indicates various parts of the pump unit. The Series S range has a universal gearbox design in models S1 - 4. This enables the flexibility of mounting pumps with the inlet and outlet ports in either a vertical or horizontal plane.
2. Safety 2.1 Important information 2.2 Warning signs Unsafe practices and other important information are emphasized in this manual. Warnings are emphasized by means of special signs. Always read the manual before using the pump! WARNING! Indicates that special procedures must be followed to avoid severe personal injury. CAUTION! Indicates that special procedures must be followed to avoid damage to the pump. NOTE! Indicates important information to simplify or clarify practices.
2.3 Safety precautions All warnings in the manual are summarised on this page. Pay special attention to the instructions below so that severe personal injury or damage to the pump are avoided. Installation - Always observe the technical data (see chapter 5). - Never start in the wrong direction of rotation with liquid in the pump. - Never put your hands or fingers inside the port connections or anywhere close to rotating shafts.
3. Installation 3.1 Unpacking, Handling and Storage Step 1 Refer to the pump weights guide (chapter 5) before selecting and using any lifting gear. The drawings show how the pump should be lifted. Ensure that lifting equipment is correctly rated and used within these limits. Pump with drive unit Bareshaft pump Step 2 On receipt always: - Check the delivery note against the goods received. - If motorised, check that the drive instructions are available.
3.2 System design and installation 3. Installation Step 1 When designing the pumping system: - Confirm the Net Positive Suction Head requirements of the pump (NPSHr) are met by the system, 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. - Protect the pump against blockage from hard solid objects e.g. nuts, bolts etc.
3. Installation 3.
3.2 System design and installation Step 5 The pump will not be supplied pre-filled with oil therefore this table must be used to select recommended oil. Oil changing: Oil level must be checked with the pump static. First change: After 150 hours of operation, thereafter every 3000 hours of operation. Oil filling: Fill with oil through the filler plug to the level indicated in the sight glass. NOTE! On horizontally ported pumps the sight glass must be fitted to the upper hole on the side of the gearcase.
3. Installation 3.3 Flushed seal arrangements and pre-start up checks Step 1 A flushed seal arrangement is fitted in order to cool or clean the seal area. It is important that: - The flush is correctly connected (see below). - A compatible flushing fluid is used and 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 at the same time/after stopping the pump.
3.3 Flushing seal arrangement and pre-start up checks 3. Installation Step 4 Flushing fluid The choice of flushing fluid is dependent upon the fluid being pumped 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 pump supplier. Step 5 Flusing pressure and flow rate Single mechanical seal 0.5 bar (7 psi) maximum.
4. Maintenance 4.1 Cleaning in place (CIP) The pump can be manually cleaned or cleaned in place (CIP). The following is an example of a typical CIP procedure. However specific advice for each application should be sought from the pump supplier. Typical CIP procedure 1. Flush through the system with cold water or bore water (6°) (43°F). 2. Run hot caustic soda (70-80°C) (158-176°F) at 2.5% dilution through the system for 20-30 minutes. 3. Final flush through with cold water again.
4.2 Maintenance schedule 4. Maintenance It is advisable to install pressure gauges on both sides of the pump so that any problems within the pump/pipework can be monitored. Maintenance schedule Your weekly schedule should include: - Checking the oil level in the gearcase with the pump stationary. - Checking the seals for leakage and replacing as necessary. - Checking the oil seals for leakage. - Check pumping pressures.
4. Maintenance 4.3 Disassembly Step 1 Before disassembling the pump refer to safety precautions. See exploded view drawings (chapter 6). Removing rotorcase cover Remove rotorcase cover nuts (13) and cover (12). Step 2 Removing rotors 1. Insert a plastic/wooden block between the two rotors (17) to stop them turning. 2. Remove rotor retention nuts (22) and rotors.
4.3 Disassembly Step 5 Removing seal retainers 1. Remove screws (15). 2. Then remove seal retainers (14) - as a liquid sealant has been used a lever may be required to remove retainers. 3. The lip seals (16) can be removed using a screwdriver/ lever once the seal retainers are removed. It is essential to renew the lip seals and it is recommended that new gaskets or sealant be used prior to reassembly. Step 6 Removing Gearcase Cover 1. Remove screws (6). 2.
4. Maintenance 4.3 Disassembly Step 9 Bearing removal 1. Hold the shafts (24 and 25) in a vice using soft jaws to protect the areas where the seals will be located. 2. Remove the bearing nuts (30) with a ‘sharp tap’ on a ‘C’ spanner. The nuts may be tight all the way off as they are fitted with thread locking adhesive. 3.
4.4 Assembly 4. Maintenance 4.4.1 Fitting bearings to shafts Take care not to damage shaft surfaces, in particular where the seals will be located. Ensure all fasteings are tightened to torque settings as shown in Technical Data (chapter 5). On models S1, 2 and 3 pumps, bearings do not require heating. For models S4, 5 and 6 pumps, heat the bearing inner cones to 110°C (230°F). Do not use any form of live flame when heating, as this will damage bearings.
4. Maintenance 4.4 Assembly 4.4.2 Fitting Shaft Assemblies Step 1 Replace the shaft abutment spacer (27) in: - On models S1, 2, 3 and 4 and horizontally ported 5 and 6 pumps, the bearing bore opposite the rotorcase mounting face with the additional machining mark. - On models S5 and 6 vertically ported pumps, the right hand bearing bore when viewed from the front of the pump. Step 2 Identify drive and auxillary shaft positions according to gearcase cover (5) orientation. Step 3 1.
4.4 Assembly 4.4.4 Checking rotor abutment alignment Step 1 Incorrect setting of rotor alignment will damage the pump. Fit rotors onto shafts (24 and 25) and tighten rotor retention nuts (22). Step 2 1. Using a depth micrometer ensure axial alignment is within tolerance of 0.012mm (0.0005 in). 2. If the alignment is incorrect, the shaft abutment spacer (27) must be replaced/machined. 4.4.5 Fitting timing gears Step 1 Slide timing gears (36) onto shafts (24 and 25), realigning timing marks. Step 2 1.
4.4 Assembly 4. Maintenance 4.4.6 Adjusting rotor timing Step 1 If the rotor timing requires adjustment (and assuming the pump has not yet been re-built), it is important to establish the cause for the rotors mistiming before proceeding. To allow timing adjustment ensure that one shaft is able to rotate within the torque locking assembly/element. The other torque locking assembly/element should be tightened to the recommended torque.
4. Maintenance 4.4 Assembly 4.4.7 Fitting gearcase cover Step 1 Clean the gearcase cover bore and remove all gasket material from the face. Press a new lip seal (7) into the cover (5). Step 2 Apply liquid gasket to the face of the cover where it mates with the gearcase. Step 3 Carefully slide the cover over the shaft ensuring the lip seal is centred and not cut or damaged. Tighten the screws (6). 4.4.
4.4 Assembly 4. Maintenance 4.4.9 Fitting primary seals Step 1 Refer to section 4.5 for seal fitting instructions. 4.4.10 Fitting rotors Step 1 1. Fit new rotor O rings (18). 2. Fit rotors (17) onto the shafts (24 and 25) with both dimpled rotor master lobes in the 6 -12 o’clock position (horizontally ported pumps) or 3-9 o’clock position (vertically ported pumps).
4.5 Primary seals removal and fitting 4. Maintenance 4.5.1 R90 Single mechanical seal Mechanical seals are fragile. Take extreme care when handling. Clean components before fitting, checking there is no damage to sealing faces. New elastomeric parts should be fitted during assembly. 7 Pump Setting Dimension in mm 1 Stationary seal ring O-ring S1 33.6 1.32 2 Stationary seal ring S2 35.6 1.40 3 Rotary seal ring S3 38.1 1.50 4 Rotary seal ring O-ring S4 39.6 1.
4. Maintenance 4.5 Primary seals removal and fitting 4.5.2 R90 Single flushed/quench mechanical seal Item Description 1 Stationary seal ring O-ring 2 Stationary seal ring 3 Rotary seal ring 4 Rotary seal ring O-ring 5 Wave spring 6 Drive ring 7 Spacer O-ring 8 Spacer 9 Gasket 10 Seal housing 11 Lip seal 12 Grub screw 12 Seal removal: 1. Turn off the flush and disconnect the flushing pipework. 2. Loosen screws (12) through the flushing connections. 3.
4.5 Primary seals removal and fitting 4. Maintenance 4.5.3 R90 Double flushed mechanical seal 14 Item Description 1 Stationary seal ring O-ring 2 Stationary seal ring 3 Rotary seal ring 4 Rotary seal ring O-ring 5 Wave spring 6 Drive ring 7 Wave spring 8 Rotary seal ring O-ring 9 Rotary seal ring 10 Stationary seal ring 11 Gasket 12 Stationary seal ring O-ring 13 Seal housing 14 Grub screw Gearcase side Rotorcase side Outboard Inboard Inboard Seal removal: 1.
4. Maintenance 4.5 Primary seals removal and fitting 4.5.4 Hyclean single mechanical seal Item Description 1 Rotorcase O-ring 2 Wave spring 3 Shaft O-ring 4 Stationary seal ring 5 Rotary seal ring 6 Washer 7 Clip 8 Seal removal: 1. Remove the rotorcase. 2. Remove clips (7) and stationary seals (4) from rotorcase. 3. Remove rotary seals (5) and O-rings (3) from shafts. Seal fitting: 1. Lightly lubricate the O-rings (3 and 1) and fit to shafts and rotorcase. 2.
4.5 Primary seals removal and fitting 4.5.5 Hyclean single flushed/quench mechanical seal Item Description 1 Rotorcase O-ring 2 Wave spring 3 Shaft O-ring 4 Stationary seal ring 5 Rotary seal ring 6 Washer 7 O-ring 8 Seal housing 9 Lip seal Seal removal: 1. Turn off the flush and disconnect the flushing pipework. 2. Remove the rotorcase. 3. Remove seal housings (8), stationary seals (4) and O-rings (1) from rotorcase. 4. Remove rotary seals (5) and O-rings (3) from shafts.
4. Maintenance 4.5 Primary seals removal and fitting 4.5.6 Packed gland 10 Item Description 1 Shaft sleeve O-ring 2 Shaft sleeve 3 Spacer 4 Packing rings 5 Lantern ring (if fitted) 6 Gasket 7 Gland housing 8 Gland follower 9 Ring slinger 10 Screw Packed gland removal: 1. Loosen gland follower nuts. 2. Remove rotorcase with gland housing (7), packing (4) and gland follower (8) still assembled. 3. Loosen shaft sleeve screws (10) and remove sleeves (2) from shafts.
4.6 Pressure relief valve 4. Maintenance The relief valve must not be disassembled whilst the pump is in operation. Always observe the safety precautions detailed at the front of this manual. Take extreme care when removing the springs as they may be compressed.
4. Maintenance 4.6 Pressure relief valve Relief Valve Disassembly 1. Remove manual override lever if fitted. 2. Remove screws (25) and valve housing (24). 3. Remove notched nut(s) (23) and spring adjuster (21). If springs are still compressed when the notched nut reaches end of thread, release the spring adjuster screws (26). 4. Remove springs (18) (models S1-5), spring stacks (models S6), screws and valve guide (16). 5. Remove circlip (14) and pneumatic piston (12). 6.
4. Maintenance 4.7 Troubleshooting No flow Under capacity Irregular discharge Low discharge pressure Pump will not prime Prime lost after starting Pump stalls when starting Pump overheats Motor overheats Excessive power absorbed Noise and vibration Pump element wear Syphoning Seizure Mechanical seal leakage Packed gland leakage Problem 9 9 9 Probable Causes Incorrect direction of rotation. Pump not primed. 99 9 9 9 9 Insufficient NPSH available. 9 9 9 9 9 Fluid vaporising in suction line.
5.1 Technical data 5. Technical data 5.1.1 Oil capacities Pump model Port orientation Port orientation Vertical litres Horizontal litres Vertical US pints Horizontal US pints S1 S2 S3 S4 S5 0.28 0.55 1.05 1.50 5.00 0.38 0.65 1.48 2.00 0.60 1.20 2.20 3.20 10.60 0.80 1.40 3.10 4.20 S6 8.50 0.62 (top chamber) 1.38 (bottom chamber) 1.30 (top chamber) 2.30 (bottom chamber) 1.30 (top chamber) 2.90 (bottom chamber) 2.80 (top chamber) 4.90 (bottom chamber) 18.00 5.1.
6.1 S1-3 Pump Parts List Pos.
6. Parts list This page shows an exploded drawing of S1-3. 6.1 S1-3 Pump The drawing includes all items of the pump.
6.2 S4 Pump Parts List Pos.
6. Parts list This page shows an exploded drawing of S4. 6.2 S4 Pump The drawing includes all items of the pump.
6.3 S5 Pump - Horizontally Ported Parts List Pos.
6. Parts list This page shows an exploded drawing of S5 - horizontally ported. 6.3 S5 Pump - Horizontally Ported The drawing includes all items of the pump.
6.4 S5 Pump - Vertically Ported Parts List Pos.
6. Parts list This page shows an exploded drawing of S5 - vertically ported. 6.4 S5 Pump - Vertically Ported The drawing includes all items of the pump.
6.5 S6 Pump - Horizontally Ported Parts List Pos.
6. Parts list This page shows an exploded drawing of S6 - horizontally ported. 6.5 S6 Pump - Horizontally Ported The drawing includes all items of the pump.
6.6 S6 Pump - Vertically Ported Parts List Pos.
6. Parts list This page shows an exploded drawing of S6 - vertically ported. 6.6 S6 Pump - Vertically Ported The drawing includes all items of the pump.
Alfa Laval Pumps Ltd Birch Road, Eastbourne East Sussex BN23 6PQ, England Tel: +44 (0) 1323 412555 Fax: +44 (0) 1323 414515 www.ssppumps.com The information contained herein is correct at the time of issue but may be subject to change without prior notice.
