HLR Rotary Lobe Pump
Contents
1. ZAR ee EE MB 8 9 MER A ET 2010 09 2 Index SOURCE OF SOLUTIONS 3 General nformation 3 1 DESCRI PTION The HLR rotary lobe pumps by INOXPA are part of our wide range of positive displacement rotary lobe pumps for viscous liquids The following models exist in the hygienic rotary lobe pump range e The HLR pump normal flow rate suitable for differential pressure of up to 12 bar e TheHLR with wider lobes delivers a higher flow rate and is suitable for differential pressure of up to 7 bar The HLR model has been specially developed to respond to all hygienic requirements in the Bio Pharm and Food industries As regards hygiene reliability and sturdiness the complete range of rotary lobe pumps satisfies all requirements set by the aforesaid industries Its modular design enables optimal part interchange between the different pumps The rotary lobe pumps are positive displacement pumps Owing to the contact between the internal parts the pressure variations etc they make a louder noise than centrifugal pumps This noise must be taken into consideration when installing these pumps The HLR rotary lobe pumps by INOXPA have been certified by EHEDG and designed so that they meet the requirements of 3A Sanitary Authority This equipment is suitable for use in food processing applications with strict hygienic requirements 3 2 OPERATING PRI NCI PLE2. NY ta a to H FP gt Ner ACOA AARAA HH c SOURCE OF SOLUTIONS AISI 316L AISI 316L AISI 316L AISI 329 AISI 329 GG 22 SiC C EPDM GG 22 GG 22 ST 52 ST 52 Klingerit F 154 F 154 AISI 316L SS AISI 316L AISI 304 PET Plus A2 A2 8 8 8 8 A2 A2 A2 A2 F 522 A2 F 114 AISI 304 Steel Steel Steel Steel Steel Steel 70 EPDM 70 EPDM 70 EPDM EPDM 72 NBR Plastic Plastic Plastic 72 NBR 72 NBR ED 2010 09 8 Technical Specifications 41 8 9 HLR 4 8 9 1 Exploded view 42 8 Technical Specifications ED 2010 09 8 9 2 Spare parts list 01 Rotor case 1 AISI 316L HLR 4 100 short HLR 4 150 large 02 Rotor 2 AISI 316L HLR 4 100 short HLR 4 150 large 03 Front cover 1 AISI 316L 05 Drive shaft 1 AISI 329 05 Driven shaft 1 AISI 329 06 Gear case 1 GG 22 07A Support 2 AISI 304 08 Mechanical seal 2 SiC C EPDM 12 Bearing cover 1 GG 22 12A Bearing stop flange 2 GG 22 17 Drive shaft bushing 1 ST 52 17D Drive shaft bushing 1 ST 52 19 Driver shaft gear 1 F 154 19A Driven shaft gear 1 F 154 25 Lobe screw 2 AISI 3161 HLR 4 100 short HLR 4 150 large 32 Shim SS 35A Seal washer 8 AISI 316L 45 Wing nut 4 AISI 304 47 2 PET Plus 50 Screw 4 A2 50A Countersunk screw 8 A2 51 Allen screw 8 8 8 51E Allen screw 8 A2 52 Hex Screw 4 8
3. storage wis ive aee EAE oani La Pa 4 3 EE c oen o dacs ee roman kia md m 4 6 Secondary PIPING 4 7 Pressure relief valVe iius ch sini 4 8 Electrical nii uu BENENNEN Start up Er X ETT 5 2 Pressure 5 eene eue ve sabe Beda Cea d Fa ae Du dug Operating Problems Maintenance 7 1 General maintenance eeeeeseee nza kakaa pe SUN AGS assis PEERS 7 3 7 4 PUMP disassembly 7 5 Til EE d ecce aa kuwania L Te gu 7 7 Mechanical seal assembly and disassembly ANNE Technical Specifications 8 1 Technical specifications 8 27 Lu CT 8 3 HER GIMONSIONS eege deeg Dresden enee TEEN RENE 8 4 pump with flushing dimensions ENEE LEM HR 8 6
4. 7 1 2 Dry thread torque Dry thread torque N m ms m m mo m2 Mie mis mo 8 8 6 10 25 49 86 135 210 290 410 A2 5 9 21 42 74 112 160 210 300 7 1 3 Oiling The bearings are oiled by immersion in an oil bath The pumps are supplied with oil e Regularly check the oil level for example weekly or every 150 operating hours e The first oil change must be carried out after 150 hours of operation e Afterwards it can be changed every 2500 operating hours or at least once a year when operating under normal conditions When change the oil the oil sump must be filled up to the level in the middle of the peephole A Do not pour too much oil into the sump Leave the pump switched off for a while and then re check the oil level if necessary add a little oil Oils for environment temperatures of 5 to 50 C SAE 90 or ISO VG 220 Quantity of oil in the gear case I 7 2 STORAGE Before being stored the pump must be completely emptied of liquids Avoid as far as possible the exposure of the parts to excessively damp atmospheres HLR O 0 3 HLR 1 0 5 HLR 2 0 75 HLR 3 1 75 HLR 4 4 5 16 7 Maintenance ED 2010 09 SOURCE OF SOLUTIONS A The use of aggressive cleaning products such as caustic soda and nitric acid may give rise to skin 7 3 CLEANI NG 7 3 1 Manual cleaning burns Use rubber gloves during the cleaning
5. Note Pumps size 0 Be sure that shaft sleeves 13 are already assembled on the pump before mounting the mechanical seal e Mount the rotary assembly 01 to the lobe rotor ensuring that the pins of the lobe rotor engage with the slots of the rotary assembly and it remains perfectly flat e Clean the working surfaces with solvent Reassemble the lobe rotor according to 7 5 5 Lobe assembly e See paragraph 7 6 3 Lobe Pump Rotor case adjustment using shims 26 7 Maintenance ED 2010 09 7 7 SOURCE OF SOLUTIONS 2 Balanced double mechanical seal Mechanical seals are fragile parts Take care when handling them N X VLE SL 03 O ring LA 7 N ND y J NN ec 16 04 Washer NN NS SN NS SS 05 Static Holder KAS TS 4 Gals AN 06 Insert 07 Insert 08 O ring 2 03 4 8 j 09 Grub screw Do not use any screwdriver or similar tool to pull out the parts Clean all the components of the mechanical seal before placing them Check that the working surfaces are not damaged INOXPA recommends replacing the entire mechanical seal if one of the working surfaces has a defect Replace the O rings during assembly Description Double mechanical seal 01 Rotary part 02 Stationary part 10 Drive ring 11 Wave Spring 12 Rotary Holder 13 Wave Spring 14 O ring Disassembly Pump size 0 Remove the shaft sleeve 13 mounted on each shaft Sleeves are not interchange
6. e After unit is installed recheck alignment of pump and motor shaft and alignment of piping Realign if necessary e Inthe case of applications dealing with high temperatures the pump can be operated temporarily at its working temperature Then recheck alignment pump piping Place a straight edge A on top of the coupling the straight should make contact with both halves of the coupling over their entire length See figure Repeat the check but this time on both sides of the coupling near the shaft For the sake of accuracy this check should also be done using an outside caliper B at two diametrically opposite points on the outside surfaces of the two halves of the coupling ED 2010 09 4 Installation SOURCE OF SOLUTIONS Maximum alignment deviations Outside diameter of Vamax Vamin the coupling mm mm mm mm mm 70 80 2 4 0 13 0 13 81 95 2 4 w 2 2 mawo 2 23 oa oa an uo 2 a 94 9M 14 10 2 6 07 1601 130 2 6 o 181 20 2 6 oa os 20 25 2 6 4 5 5 e In general suction and delivery pipes should be fitted in straight stretches with the minimum amount of elbows accessories in order to reduce as far as possible any head loss that might be produced by friction e Make sure that the pump ports are well aligned with respect to the pipin
7. SOURCE OF SOLUTIONS INSTALLATION SERVICE AND MAI NTENANCE I NSTRUCTI ONS HLR Rotary Lobe Pump I NOXPA S A c Telers 54 Aptdo 174 E 17820 Banyoles Girona Spain Tel 34 972 57 52 00 Fax 34 972 57 5502 e mail inoxpa inoxpa com www inoxpa com o SA 150 9001 ee BUREAU VERITAS Ut Certification 7828 Original Manual 01 504 30 00EN ED 2010 09 SOURCE OF SOLUTIONS EC DECLARATION OF CONFORMITY according to Directive 2006 42 CE annex part A Manufacturer INOXPA S A C Telers 54 17820 Banyoles Girona SPAIN Hereby declares that the product LOBE ROTOR PUMP HLR Name Type conforms to the specifications of the Council Directive Machine Directive 2006 42 CE and complies with the essential requirements of the Directive and Harmonised Standards UNE EN ISO 12100 1 2 2004 UNE EN 809 AC 2001 UNE EN ISO 13857 2008 UNE EN 953 1997 UNE EN ISO 13732 2007 Low Voltage Directive 2006 95 EC what repeal 73 23 CEE Directive and are conforms with UNE EN 60204 1 2006 and UNE EN 60034 1 2004 EMC Directive 2004 108 EC what repeal 89 336 CEE Directive and are conforms with UNE EN 60034 1 2004 In compliance with the Regulations CE 1935 2004 relating to materials and articles intended to come into contact with foodstuff repeal Directive 89 109 CEE the materials in contact with the product do not transfer their components in quantities which may jeopardis
8. The rotary lobe pump is a positive displacement rotary pump The left lobe except in the case of pump size 0 is driven by the driving shaft The right lobe except in the case of pump size 0 is located on the driven shaft and is driven via a helical gear Both lobes rotate in synchronism without one touching the other When the pump is running they displace a set volume of liquid Figure below shows how a rotary lobe pump operates ch ERY d 0 Le AY CRs y e 4 When the lobes rotate the space the suction side increases because one lobe moves away from the other thus causing a partial vacuum that draws the liquid into the pumping chamber B Each lobe void is filled consecutively as the shafts rotate and the liquid is displaced towards the discharge side The small clearances between the lobes and between the lobes and the walls of the rotor case duly cause the spaces to be rather well closed C The rotor case is completely full and the liquid leaks through the meshing of the lobes knocking against the space walls so as to thus complete the pumping action 3 3 APPLICATION The main advantage of the INOXPA HLR rotary lobe pump is its capacity to pump a great variety of viscous liquids from 1 mPa s up to 100 000 mPa s Furthermore it is capable of pumping liquid products that require very careful handling and liquids that contain soft solids thus causing only a minimum degradatio
9. 2 70 EPDM Splash ring 2 EPDM Blanking plug 1 72 NBR Oil plug 1 Plastic Peephole 1 Plastic Bleeder 1 Plastic Lip seal 1 72 NBR Lip seal 2 72 NBR Quantity of shims may vary from one pump to another SOURCE OF SOLUTIONS ED 2010 09 8 Technical Specifications 39 8 8 HLR 3 8 8 1 Exploded view 40 8 Technical Specifications ED 2010 09 8 8 2 Spare parts list 01 02 03 05 05 06 08 12 12 17 17 18 19 19 25 32 35A 45 47A 50 50A 51 52 53 53A 54A 55A 56 56B 61 61A 62 63 65A 66 70 70A 80 80A 80B 82 84 85 86 87 88 1 Rotor case HLR 3 50 short HLR 3 80 large Rotor HLR 3 50 short HLR 3 80 large Front cover Drive shaft Driven shaft Gear case Mechanical seal Bearing cover Bearing stop flange Drive shaft bushing Driven shaft bushing Bearing cover gasket Driver shaft gear Driven shaft gear Lobe screw HLR 3 50 short HLR 3 80 large Shim Seal washer Wing nut Protector Screw Countersunk screw Allen screw Hex Screw Flat washer Grower washer Hexagonal nut Stud Pin Pin Key Key Safety nut Safety washer Conical tightening ring Circlip Ball bearings Needle bearings O ring Front cover gasket O ring Splash ring Blanking plug Oil plug Peephole Bleeder Lip seal 89 Quantity of shims may vary from one pump to another Lip seal NPP RP
10. 213 21856363 21851780 Fax 213 21854431 e mail inoxpalgerie inoxpa com INOXPA UK LTD SURREY Tel 44 1737 378 060 079 Fax 44 1737 766 539 e mail inoxpa uk inoxpa com INOXPA SKANDINAVIEN A S HORSENS DENMARK Tel 45 76 286 900 Fax 45 76 286 909 e mail inoxpa dk inoxpa com INOXPA SPECI AL PROCESSING EQUIPMENT CO LTD JIAXING China Tel 86 573 83 570 035 036 Fax 86 573 83 570 038 INOXPA WI NE SOLUTIONS VENDARGUES FRANCE Tel 33 971 515 447 Fax 33 467 568 745 e mail frigail fr inoxpa com npourtaud fr inoxpa com DELEGACI ON NORD ESTE BARBERA DEL VALLES BCN Tel 937 297 280 Fax 937 296 220 e mail inoxpa nordeste inoxpa com DELEGACI ON CENTRO ARGANDA DEL REY MADRID Tel 918 716 084 Fax 918 703 641 e mail inoxpa centro inoxpa com LOGRONO Tel 941 228 622 Fax 941 204 290 e mail sta rioja inoxpa com INOXPA SOLUTIONS FRANCE GLEIZE Tel 33 474627100 Fax 33 474627101 e mail inoxpa fr inoxpa com WAMBRECHIES Tel 33 320631000 Fax 33 320631001 e mail inoxpa nord fr inoxpa com INOXPA SOUTH AFRICA PTY LTD JOHANNESBURG Tel 27 117 945 223 Fax 27 866 807 756 e mail sales inoxpa com S T A PORTUGUESA LDA VALE DE CAMBRA Tel 351 256 472 722 Fax 351 256 425 697 e mail comercial pt inoxpa com IMPROVED SOLUTI ONS VALE DE CAMBRA Tel 351 256 472 140 138 Fax 351 256 472 130 e mail isp pt inoxpa com INOXRUS MOSCOW RUSIA Tel F
11. 8 53 Flat washer 4 A2 53A Grower washer 4 A2 54A Hexagonal nut 4 A2 55A Stud 4 A2 55B Stud 4 A2 56 Pin 4 F 522 56A Pin 2 F 522 56B Pin 4 A2 61 Key 1 F 114 61A Key 1 AISI 304 62 Safety nut 2 Steel 63 Safety washer 2 Steel 65 Conical tightening ring 1 Steel 66 Circlip 1 Steel 70 Ball bearings 2 Steel 70A Needle bearings 2 Steel 70B Axial bearings 4 Steel 70C Axial disc 4 Steel 70D Intermediate disc 2 Steel 80 O ring 2 70 EPDM 80A Front cover gasket 1 70 EPDM 80B O ring 2 70 EPDM 80E O ring 1 MVQ 80F O ring 2 FPM 82 Splash ring 2 EPDM 84 Blanking plug 1 72 NBR 85 Cil plug 1 Plastic 86 Peephole 1 Plastic 87 Bleeder 1 Plastic 88 Lip seal 1 72 NBR 89 Lip seal 2 72 NBR Quantity of shims may vary from one pump to another SOURCE OF SOLUTIONS ED 2010 09 8 Technical Specifications 43 SOURCE OF SOLUTIONS S A c Telers 54 PO Box 174 17820 BANYOLES GIRONA Tel 34 972575200 Fax 34 972575502 e mail inoxpa inoxpa com www inoxpa com DELEGACI ON LEVANTE PATERNA VALENCIA Tel 963 170 101 Fax 963 777 539 e mail inoxpa levante inoxpa com LA CISTERNIGA VALLADOLID Tel 983 403 197 Fax 983 402 640 e mail sta valladolid inoxpa com NOXPA SOLUTIONS LEVANTE PATERNA VALENCIA Tel 963 170 101 Fax 963 777 539 e mail ST SEBASTIEN sur LOIRE Tel Fax 33 130289100 e mail inoxpa fr inoxpa com ALGERI E ROUIBA Tel
12. and standard lobe rotor clearances To consult for higher temperatures 2 The maximum viscosity allowed will depend on the nature of the liquid and the sliding speed of the seal faces Consult INOXPA should the viscosity be still greater A Use special protection when the noise level in the operation area exceeds 85 dB A RET REST m h bar ny s ny s HLR 0 20 47 8 HLR 0 25 950 29 47 8 x x 7 2 T mri 99 30 mnia s Lei so man ss s Mas 70 5 ms Nmax Maximum speed Lobe width Di Lobe diameter Vun Theoretical displacement volume x 100 rev Theoretical flow rate at ni Prax Maximum differential pressure Vu Peripheral speed Vi Maximum inlet velocity 28 8 Technical Specifications ED 2010 09 Materials Product wetted Parts eterne eran Other parts in stainless steel Product wetted gaskets ENNEN Other materials for optional Product wetted parts surface finishing Mechanical seal bou EA AAA AA AAA Rotary parts material Stationary parts material NEEN Elastomers material EN Cooled mechanical seal Working AA awa Flow rate of the circulation Double mechanical seal TYPE Of Sealand aonana de enn i Re nea nnb kenne dns Due to the balanced design no over pressur
13. electric charge even when disconnected Contact with them may put the safety of operators at risk or cause irreparable damage to the material Before manoeuvring the pump make sure that the electric box is switched off V The electrical equipment the terminals and the components of the control systems may still carry an e Connect the motor in accordance with the instructions supplied by the manufacturer of the same Check the direction of the rotation see the signalling label on the pump Start the pump motor briefly Make sure the pumping direction is the right one If the pump operates in the wrong direction it may cause severe damage Pumps size 1 2 3 and 4 Pumps size 0 Check ALWAYS the direction of the motor s rotation with liquid inside the pump For the models with sealing chamber make sure always that it is filled of liquid before checking the rotating direction 12 4 Installation ED 2010 09 SOURCE OF SOLUTIONS 5 Start up Before putting the pump into operation read carefully the instructions on installation given in Chapter 4 nsta ation 5 1 START UP Read Chapter 8 Technical Specifications carefully NOXPA will not assume responsibility for any improper or incorrect use of the equipment A Do not touch the pump or the piping while it is pumping products at a high temperature 5 1 1 Checks to be carried out before putting the pump into operation e Completely open the p
14. process 2 Always use protective goggles 7 3 2 Automatic cleaning in place If the pump is installed in a system fitted with a CIP process there will be no need for stripping The recommended minimum liquid speed for an effective process of cleaning is 1 8 m s minimum Re gt 100 000 at 1 0 2 5 bar It is recommended to run the pump during the CIP process rotation speed nominal speed at 50 Hz If it is not fitted with an automatic cleaning process strip the pump pursuant to the instructions given in the section entitled Stripping and Assembly of the pump Cleaning solutions for CIP processes Only use clear water chloride free to mix with the cleaning agents a Alkaline solution 1 in weight of caustic soda NaOH to 70 C 150 F 1 kg NaOH 100 water cleaning solution or 2 2 NaOH to 33 100 of water cleaning solution b Acid solution 0 5 in weight of nitric acid to 70 C 150 F or 0 7 litres HNOs to 53 100 water cleaning solution Monitor the concentration of cleaning solutions it could give rise to the deterioration of the pump sealing gaskets These solutions are given as examples and should be validated before use on an application In order to remove any remains of cleaning products ALWAYS rinse the element in question with clean water after completing the cleaning process 7 3 3 Automatic SIP sterilization in place The process of sterilizat
15. the parts which are used are not damaged during transport When doing this you need to inspect the adjustment edge the butted faces the tight fit burrs etc After each disassembly carefully clean the parts and check for any damage Replace all damaged parts Tools Use the proper tools for assembly and disassembly operations Use them correctly Cleaning Before disassembling the pump clean it on the outside and on the inside A NEVER clean the pump by hand when it is running 7 4 1 Pump cover disassembly A CAUTI ON Liquid may spill from the rotor case when removing the pump cover Close the suction and delivery valves Remove the cap nuts 45 Indents have been provided at four 4 points around the perimeter of the pump cover 03 to assist if 77 necessary in removing it from the rotor case that is with the help of a screwdriver Check that the seal 80A is in good condition 7 4 2 Lobe disassembly Loosen the lobe screws 25 using a spanner This spanner can be requested from INOXPA See spare parts list Document P 01 504 31 000 These screws have a right hand thread In order to prevent the lobes from turning simultaneously blocks of wood or plastic can be placed between the lobes Check that the O ring 80 is in good condition Remove both lobes 02 If necessary use a tool to assist for this purpose Pumpsize 1 2 3 4 Remove shims 32 moun
16. the pump in such a way that it can be properly ventilated I f the pump is to be installed A and maintenance operations that may need to be carried out 4 3 1 Foundation Install the pump base so that the drive and pump are level and well supported Therefore the pump unit should be installed on a base plate according to DIN 24259 or on a frame both placed exactly level on the foundation The foundation must be hard level flat vibrations free to prevent base distortion to keep the alignment pump drive guaranteed while commissioning To install the pump unit on the foundation proceed as follows e Make holes in the foundation to fit foundation bolts This is unnecessary when expanding screws are used instead of foundation bolts e Place base plate or frame with the aid of shims horizontally on the foundation e Grout e When the grout has entirely hardened the pump unit can be placed on the base plate or the frame Tighten the nuts on the foundation bolts carefully For other foundations consult INOXPA 4 4 COUPLING For the couplings selection and assembly consult to the supplier manual Sometimes the torque of the positive displacement pumps can be high enough Therefore a coupling have been chosen 1 5 to 2 the adequate torque 4 4 1 Alignment The pump and motor shaft of complete units have been accurately pre aligned in our factory A After installations of the pump unit the pump and motor shaft should be re aligned
17. ED 2010 09 8 5 2 Spare part list 01 02 03 05 05 06 07 08 12 12 13 17 17 19 19 25 35A 45 47A 50 51 51A 51B 51C 51E DIF 55A 56 56B 61 61A 62 63 65A 70 70A 80 80A 80D 80E 85 86 87 88 Rotor case 1 AISI 316L HLR 0 20 short HLR 0 25 large Rotor 2 AISI 316L HLR 0 20 short HLR 0 25 large Front cover 1 AISI 316L Drive shaft 1 AISI 329 Driven shaft 1 AISI 329 Gear case 1 GG 22 Support vertical port 1 F 1 Mechanical seal 2 SiC C EPDM Bearing stop flange 2 GG 22 Back cover 1 GG 22 Sleeve seal 2 AISI 316L Drive shaft bushing 1 ST 52 Dragging bushing 1 ST 52 Driver shaft gear 1 F 154 Driven shaft gear 1 F 154 Lobe screw 2 AISI 316L HLR 0 20 short HLR 0 25 large Seal washer 8 AISI 316L Wing nut 4 AISI 304 Protector 1 PET Plus Screw 2 A2 Allen screw 6 8 8 Allen screw 6 8 8 Allen screw 4 8 8 Allen screw 4 8 8 Allen screw 4 A2 Allen screw 8 A2 Stud 4 A2 Pin 2 F 522 Pin 4 A2 Key 1 F 114 Key 1 AISI 304 Safety nut 2 Steel Safety washer 2 Steel Conical tightening ring 1 Steel Ball bearings 2 Steel Needle bearings 2 Steel O ring 2 70 EPDM Front cover gasket 1 70 EPDM O ring 2 70 EPDM O ring 1 NBR Oil plug 1 Plastic Peephole 1 Plastic Bleeder 1 Plastic Lip seal 1 72 NBR Lip seal 2 72 NBR 89 SOURCE OF SOLUTIONS ED 2010 09 8 Technical Specifications 35 8 6 HLR 1 8 6 1 Exploded view 36 8 Technical
18. Specifications ED 2010 09 8 6 2 Spare parts list 01 02 03 05 05 06 08 12 12 17 17 17 18 19 19 25 32 35A 45 47A 50 51 51A 51D 51F 53 54A 55A 55B 56 56B 61 61A 62 63 65A 66 70 70A 80 80A 80B 82 84 85 86 87 88 89 Rotor case 1 AISI 316L HLR 1 25 short HLR 1 40 large Rotor 2 AISI 3161 HLR 1 25 short HLR 1 40 large Front cover 1 AISI 316L Drive shaft 1 AISI 329 Driven shaft 1 AISI 329 Gear case 1 GG 22 Mechanical seal 2 SiC C EPDM Bearing cover 1 GG 22 Bearing stop flange 2 GG 22 Drive shaft bushing 1 ST 52 Driven shaft bushing 1 ST 52 Dragging bushing 1 ST 52 Bearing cover gasket 1 Klingerit Driver shaft gear 1 F 154 Driven shaft gear 1 F 154 Lobe screw 2 AISI 316L HLR 1 25 short HLR 1 40 large Shim 9 55 Seal washer 8 AISI 316L Wing nut 4 AISI 304 Protector 1 PET Plus Screw 2 A2 Allen screw 8 8 8 Allen screw 8 8 8 Allen screw 4 8 8 Allen screw 8 A2 Flat washer 4 A2 Hexagonal nut 4 A2 Stud 4 A2 Stud 4 A2 Pin 4 F 522 Pin 4 A2 Key 1 F 114 Key 1 AISI 304 Safety nut 2 Steel Safety washer 2 Steel Conical tightening ring 1 Steel Circlip 1 Steel Ball bearings 2 Steel Needle bearings 2 Steel O ring 2 70 EPDM Front cover gasket 1 70 EPDM O ring 2 70 EPDM Splash ring 2 EPDM Blanking plug 1 72 NBR Oil plug 1 Plastic Peephole 1 Plastic Bleeder 1 Plastic Lip seal 1 72 NBR Lip seal 2 72 NBR Quantity of shims may va
19. able Remember the shaft each sleeve was mounted on Pump size 1 2 3 4 Remove the shims 32 mounted on each shaft If more than one is mounted on each shaft keep them separate to prevent them from getting mixed up Normally the Rotary Assembly 01 remains housed in the lobe rotor during disassembly Remove them carefully Remove the stationary parts 02 05 from the rotor case bores along Please proceed carefully Remove the 4 seal washers located to the rear of rotor case Or 4 Allen screws at pump size 0 Loosen the grub screws 09 Remove carefully the rotary holder 12 and the drive ring 10 from the shafts along Assembly Pump size Fit the shaft sleeves 13 each origin shaft Pump size 1 2 3 4 Fit the shims 32 on each origin shaft Lubricate all the O rings of the mechanical seal with soapy water or oil compatible with the material of the seals Note Pump size 0 Be sure that shaft sleeves 13 are already assembled on the pump before mounting the mechanical seal Mount the drive ring 10 and the rotary holder 12 onto the pump shafts as far as they will go and fix them to the shafts with the grub screws 09 Clean the working surfaces with solvent Mount the 4 seal washers located to the rear of rotor case Or 4 Allen screws at pump size 0 Mount the drive ring 05 into the rotor case bore taking care to align it with the 4 seal washer located in the back of the rotor case Fit the st
20. ationary part 02 with the drive ring 05 into the rotor case bore ensuring that the pins of the drive ring 05 engage with the biggest slots of stationary part 02 Mount the rotary assembly 01 to the lobe rotor ensuring that the lobe pins engage with the slots of the rotary face 01 and it remains perfectly flat Clean the working surfaces with solvent Reassemble the lobe rotor according to 75 5 Lobe assembly See paragraph 7 6 3 Lobe Pump Rotor case adjustment using shims ED 2 010 09 7 Maintenance 27 SOURCE OF SOLUTIONS 8 Technical Specifications 8 1 TECHNICAL SPECI FI CATI ONS Short rotor Long rotor Theoretical displacement volume x 100 rev 217 litres 321 litres EE 52 m h 229 US gpm 77 m h 339 US gpm Maximum differential 04 22 12 bar 174 psi 7 bar 102 psi Maximum working 55 16 bar 232 psi 16 bar 232 psi Maximum temperature D 120 C 248 F 120 C 248 F Maximum viscosity 2 100 000 mPa s 100 000 mPa s Maximum speed aa kaka 950 950 Maximum connections eese 100 mm 4 in 150 mm 6 in Suction delivery connections eene Clamp standard Clamp standard 1 Maximum temperature for continuous application due to EPDM gaskets
21. ax 74 956 606 020 e mail moscow inoxpa com INOXPA UCRANI A KIEV Tel 38 050 720 8692 e mail kiev inoxpa com ZARAGOZA Tel 976 591 942 Fax 976 591 473 e mail inoxpa aragon inoxpa com DELEGACI N STA GALDACANO BILBAO Tel 944 572 058 Fax 944 571 806 e mail sta inoxpa com DELEGACI N SUR JEREZ DE LA FRONTERA C DIZ Tel Fax 956 140 193 e mail inoxpa sur inoxpa com CHAMBLY PARIS Tel 33 130289100 Fax 33 130289101 e mail isf inoxpa com INOXPA AUSTRALIA PTY LTD MORNINGTON VICTORIA Tel 61 3 5976 8881 Fax 61 3 5976 8882 e mail INOXPA USA Inc SANTA ROSA Tel 1 7075 853 900 Fax 1 7075 853 908 e mail inoxpa us inoxpa com INOXPA ITALIA S R L BALLO DI MIRANO VENEZIA Tel 39 041 411 236 Fax 39 041 5128 414 e mail inoxpa it inoxpa com INOXPA INDIA PVT LTD Maharashtra INDIA Tel 91 2065 008 458 inoxpa in inoxpa com SAINT PETERSBURG RUSIA Tel 78 126 221 626 927 Fax 78 126 221 926 e mail spb inoxpa com INOXPA products are available from our branch offices and through a network of independent distributors covering more than 50 countries around the World For more information visit our Web site www inoxpa com This information is given for guidance only We reserve the right to change any materials or characteristics without prior notice
22. ble on all seal types Use the sectional drawings of the HLR seal options to purchase additional parts Attention should be given to the compatibility of the handled liquid with the flush media Choose the sealing liquid so that unwanted chemical reactions are avoided Also check the compatibility of the flush media with seal elastomers HLR rotor cases have female threaded inlet and outlet connections and are dependent upon frame of the pump and type of quench system employed 4 6 2 Liquid flush media Use a flush media which is filtered free from impurities to obtain maximum service life of the seal If the product is sticky or crystalline then use media which is able to dissolve the product Connect the quench so that the inlet is at the bottom and outlet is at the top This will make a better evacuation or air or gases possible 4 6 3 Heating cooling jackets Heating cooling jackets S are available on the front cover Heating or cooling media can be provided via connections according to the next figure ED 2010 09 4 Installation 11 SOURCE OF SOLUTIONS 4 7 PRESSURE RELI EF VALVE The positive displacement lobe pumps must be protected from excess pressure when they are operating Consequently all the HLR pumps can be fitted with a stainless steel pressure relief valve or a pressure by pass 4 7 1 Protection This valve protects the pump and prevents excessively high pressure arising in the circu
23. e consumer s health or safety Dear bows Banyoles 2012 Marc Pons Bague SOURCE OF SOLUTIONS 1 Safety 1 1 INSTRUCTION MANUAL This instruction manual contains information on the reception installation operation fitting stripping and maintenance for the HLR pump The information given herein is based on the most up to date data available INOXPA reserves the right to modify this instructions manual without having to give prior notice 1 2 START UP INSTRUCTIONS This instruction manual contains vital and useful information for properly operating the pump and for keeping it in good running condition Not only should the safety instructions set forth in this chapter be carefully read before putting the pump into operation but those concerned must also familiarise themselves with the operating features of the pump and strictly adhere to the instructions given herein It is extremely important that these instructions be kept in a set place near the installation 1 3 SAFETY 1 3 1 Warning signs Danger of injury caused by rotating parts Danger for people in general of the equipment Danger Electricity Danger Caustic or corrosive agents Danger to the proper operating of the Danger Suspended loads machine Obligation to ensure safety at work Use of safety goggles obligatory gt e gt opp 1 4 GENERAL SAFETY INSTRUCTI ONS Please read the instruction manual carefully before installin
24. e is required Operating pressure if it is required by the process Heating jacket Maximum temperature EEN Maximum Dressure EEN SOURCE OF SOLUTIONS AISI 316L AISI 304 EPDM Consult your supplier lt 0 8 um Single internal balanced mechanical seal Silicon carbide Carbon EPDM 0 5 bar 73 psi 2 5 5 I min 0 7 1 3 US gpm Balanced design 1 5 2 bar 22 29 psi over the pump operating pressure 180 C 356 F 4 bar 58 psi ED 2010 09 8 Technical Specifications 29 jinas SOURCE OF SOLUTIONS 8 1 1 Size of the particles WARNI NG Only soft particles A lt 10 damage when using trilobe geometry lt 2 damage when using wing lobe geometry Internal diameter Maximum theoretical Recommended maximum connection sphere frame theoretical sphere frame mm mm mm HLR 0 20 15 8 7 5 2 5 24 78 28 3i 9 HiR250 256 9 O HiR350 48 O 385 Im 8 1 2 Torque Maximum torque in the pump shaft 8 2 WEIGHTS ea end kg HLR 0 20 12 7 HiR240 293 HiR250 man Im 20 8 Technical Specifications ED 2010 09 SOURCE OF SOLUTIONS 8 3 HLR DIMENSIONS HLR O 1 m fF 5 t TI A i 1 i 1 D N se B 1 4 MIN P vb d VC HLR 1 2 3 dc 1 T Y Y 1
25. er 03 onto the rotor case 01 and tighten the blind nuts 45 e See chapter 5 7 1 Checks to be carried out before putting the pump into operation ED 2010 09 7 Maintenance 23 SOURCE OF SOLUTIONS 7 6 LOBE ADJ USTMENT AND SYNCHRONI SI NG 7 6 1 Clearance and tolerance table 0 15 0 08 0 2 0 15 0 4 0 05 0 03 0 05 0 05 0 05 0 15 0 1 0 15 0 15 0 35 0 15 0 1 0 2 0 15 0 4 0 2 0 15 0 15 0 15 0 35 0 05 0 05 0 05 0 05 0 05 0 2 0 15 0 2 0 15 0 4 0 05 0 05 0 05 0 05 0 05 0 25 0 2 0 2 0 2 0 4 0 05 0 05 0 05 0 05 0 1 0 3 0 2 0 3 0 2 0 5 0 35 0 35 0 4 0 3 0 85 0 5 0 35 0 6 0 3 1 05 A axial clearance between the lobe and the cover B axial clearance between the lobe and the rear of the rotor case C radial clearance between the lobe and the rotor case D radial clearance between the lobes E radial clearance between the lobe and the rotor case on the suction side Dimensions in mm 7 6 2 Synchronising the lobes N Inorder to enable the lobes to be tightened it is necessary to remove the shaft assembly from the gear case except in the case of pump size 0 and mount the lobes 02 on the shafts fixing them with screws 25 e Loosen the tightening screws from the adjustable fastening mechanism for the idler gear 19A In principle the adjustable fastening mechanism is easy to disassemble It is now possible to rotate the driveshaft 05 while holding the idler s
26. eter of the suction pipe e Shorten and simplify the suction piping 3 Pump not purged Purge or fill 4 Cavitation Increase suction pressure see 2 5 The pump sucks in air Check suction pipe and all its connections 6 Suction pipe clogged Check the suction pipe and filter s if any 7 Wrong setting of pressure relief valve Check the pressure relief valve s setting 8 Discharge pressure too high If necessary reduce the loss of head by increasing the diameter of the discharge pipe 9 Viscosity of the liquid is too high e Reduce the pump speed e Reduce the viscosity for example by heating the liquid 10 Viscosity of liquid too low e Increase the pump speed e Increase the viscosity for example by cooling the liquid 11 Temperature of liquid too high Reduce the temperature by cooling the liquid 12 Pump speed too high Reduce the pump speed 13 The lobes are worn Replace the lobes 14 Pump speed too low Increase the pump speed 15 Product very abrasive Fit hardened lobe hubs 16 Worn bearings Replace the bearings check the pump 17 Worn or damaged mechanical seal Replace the seal 18 O rings and gaskets are not the right ones for the Fit the proper O ring and gaskets check with the supplier liquid 19 Worn gears Replace and readjust the gears 20 Insufficient lubricating oil level Fill up with oil 21 Unsuitable lubricating oil Use an appropriate oil 22 The lobes rub e Reduce the temperature e Reduce the discharge pre
27. g and commissioning the pump Should you have any doubts or queries contact 1 4 1 During the installation You must always bear in mind the 7echnica Specifications set forth in Chapter 8 A Do not put the pump into operation before connecting it to the pipes Do not put the pump into operation if the rotor case of the pump has not been fitted and the lobe rotors fixed in the pump Check that the motor drive specifications are correct especially if there is a special risk of explosion due to the work conditions During the installation procedure all the electrical work must be carried out by duly authorised personnel 1 4 2 During operation You must always bear in mind the 7echnical Specifications set forth in Chapter 8 The limit values that A have been set must NEVER be exceeded NEVER touch the pump or pipes whenever the pump is being used to transfer hot liquids or during the cleaning procedure ED 2010 09 1 Safety 3 i SOURCE OF SOLUTIONS The pump has moving parts Do not put your fingers into the pump when it is operating NEVER work with the suction and the delivery valves shut off gt gt NEVER directly sprinkle the electric motor with water Standard motor protection is P 55 dust and water sprinkling protection 1 4 3 During maintenance You must always bear in mind the 7echnica Specifications set forth in Chapter 8 NEVER strip the pump down until the pipes have been drained Re
28. g and that they are similar in diameter to that of the pipe connections e Position the pump as near as possible to the suction tank and whenever possible below the level of the liquid or even lower with respect to the tank in order for the static suction head to be at its maximum e Place brackets for the piping as near as possible to the suction and delivery ports of the pump 4 5 1 Shut off valves The pump can be isolated for the purpose of carrying out maintenance work To this end shut off valves should be fitted at the pump s suction and delivery connections A These valves must ALWAYS be open whenever the pump is operating 4 5 2 Self priming process In general terms if the self priming process is followed the pump ought to contain sufficient liquid to fill the internal recesses and the void spaces thus enabling the pump to create a pressure difference However if low viscosity fluids are to be pumped a foot valve of the same or greater diameter as that of the suction pipe should be installed alternatively the pump can be installed with a U shaped piping A The use of a foot valve is not recommended for pumping viscous liquids e In order to eliminate air and gases from the suction pipe the counter pressure on the discharge pipe should be reduced When the self priming process is used the pump s start up should be done by opening and emptying the discharge pipe which allows the air and gases to escape at a low counte
29. h the driveshaft 05 in the left or right position just as it was before disassembling Introduce the shaft assembly into the gear case 06 taking care when sliding the shaft 05 driven by the retainer 88 Use a Nylon hammer and lightly tap the shafts 05 and 05A until the bearings cover 12 is well fixed to the gear case 06 Fix the bearings cover 12 to the gear case 06 with the washers and screws 53A and 52 Place the key 61A in the driveshaft 05 Remove the oil plug 85 located at the top of the gear case 06 Fill the gear case 06 with lubricant up to the level in the middle of the peephole 86 See 7 1 3 Oiling to consult type and quantity of oil ED 2010 09 7 Maintenance 21 SOURCE SOLUTIONS 7 5 3 Rotor case assembly CAUTION When reassembling the rotor case pay attention to the position of the centring pins Pumps Size 0 e Mount the rotor case 01 on the gear case 06 Due to the tightness of the pins it is necessary to use a Nylon hammer Lightly tap the rotor case until it is tight to the gear case e Attach the allen screws 51B e Tighten the nuts with the appropriate tightening torque Pumps Size 1 2 3 4 e Mount the rotor case 01 on the gear case 06 Due to the tightness of the pins it is necessary to use a Nylon hammer Lightly tap the rotor case until it is tight to the gear case e Attach the nuts 54A with the washers 53 e Tighten the nuts w
30. haft still 05 24 7 Maintenance ED 2010 09 Pumps size 0 1 Pumps size 2 Pumps size 3 4 Pumps Size 0 1 and 2 the adjustable fixing mechanism consists of three pieces Allen screws 51A bearing cones 65 and impeller bushing 17B Pumps Size 3 and 4 the adjustable fixing mechanism is a single piece 65 Position 1 Position 2 Slide the lobes 02 over the shafts 05 and 05 as indicated 7 5 5 Lobe assembly Turn the lobes to the position indicated in position 1 until the gap is as indicated in 76 1 Clearance and tolerance table Tighten manually several tightening screws in the adjustable fixing mechanism Then turn the left lobe about 60 in anti clockwise direction position 2 Check that the gap in this position is equal to the position 1 If not these gaps should be equalised by turning one lobe slightly while holding the other still e Tighten the tightening screws of the adjustable fixing mechanism diagonally by 2 or 3 turns with the established tightening torque e When tightening the screws of the adjustable fixing mechanism ensure that the gears 19 and 19A do not turn in relation to each other This can be avoided by placing a wooden wedge between the gears 19 19 e Check again the gap between the lobes 02 and turn the driveshaft 05 a few times in order to check that the lobes 02 do not rub against one another at any point e Remove the lobes 02 from t
31. he shafts 05 and 05 e Apply a little lubricant to the driveshaft 05 at the location of the retainer 88 once assembly is finished 7 6 3 Lobe Pump Rotor case adjustment using shims This is the final adjustment to be carried out The pump must be synchronised and the pump rotor case must be mounted on the gear case Pumps Size 0 Due to its small size and the low assembly tolerances this pump does not use shims The length of the sleeves 13 must be adjusted for each pump N Pumps Size 1 2 3 4 The adjustment is made using ring shaped shims 32 placed between shaft 05 and 05A and the lobe 02 There are 3 different shim thicknesses 0 1 0 15 and 0 2 mm Mount the lobes 02 and tighten the screws 25 as described in 7 5 5 Lobe assembly Check the tolerances between the lobe and rotor case A and B See 7 6 1 Clearance and tolerance table If they are out of range change the shims until the necessary clearance is achieved ED 2010 09 7 Maintenance 25 jinas SOURCE OF SOLUTIONS 7 7 MECHANICAL SEAL ASSEMBLY AND DISASSEMBLY 7 7 1 Single mechanical seal Mechanical seals are fragile parts Take care when handling them Do not use any screwdriver or similar tool to pull out the parts e Clean all the components of the mechanical seal before placing them e Check that the working surfaces are not damaged INOXPA recommends replacing the entire mechanical seal if one of
32. ion with steam is applied to all the equipment including the pump Do NOT start the pump during the process of sterilization with steam The parts materials suffer no damage if the indications specified in this manual are observed No cold liquid can enter the pump till the temperature of the pump is lower than 60 C 140 F A flow by pass is recommended to be used in order to assure the flow of sterile product after the pump Maximum conditions during the SI P process with steam or overheated water a Max temperature 140 C 284 F b Max time 30 min c Cooling Sterile air or inert gas d Gasket materials EPDM PTFE recommended FPM NBR not recommended ED 2010 09 7 Maintenance 17 SOURCE SOLUTIONS 7 4 PUMP DISASSEMBLY The assembly and disassembly of the pumps should only be done by qualified personnel Make sure that the personnel read carefully this instruction manual and in particular those instructions which refer to the work they will perform repair costs and a long period of down time INOXPA is not responsible for accidents or damages caused by a failure to comply with the instructions in this manual Incorrect assembly disassembly may cause damage the pump s operation and lead to high Preparations Provide for a clean working environment as some parts including the mechanical seal require very careful handling and others have close tolerances Check that
33. ipes suction and delivery shut off valves e Check oil level of the pump Add correct grade of oil as necessary to maintain level in center of oil sight glass In the case of first start up pumps are shipped with oil in the gearbox Ifthe liquid fails to flow toward the pump fill it with the liquid to be pumped A The pump must NEVER rotate without fluid inside it e Check that the power supply matches the rating indicated on the motor plate e Check that the direction of rotation of motor is the right one e If the pump has a single or double mechanical seal with buffer or barrier fluid mount the auxiliary connection corresponding to the values indicated in Chapter 8 Technical Specification 5 1 2 Checks to be carried out on putting the pump into operation e Check to make sure that the pump is not making any strange noises e Check to see if the absolute inlet pressure is sufficient in order to avoid cavitations in the pump Consult the curve for the minimum required pressure above the steam pressure NPIPr e Monitor the delivery pressure e Check that there are no leaks in the sealed areas shut off valve should not be used the suction pipe to regulate the flow rate t must completely open during operation A Monitor motor consumption in order to avoid a circuit overload Reduce flow and motor power consumption by reducing motor speed 5 2 PRESSURE BY PASS When pump has a pressure by pass pump on
34. it It reduces the differential pressure Ap between suction and discharge but not the maximum pressure within the plant Do not use the pressure relief valve to protect the system from excess pressure It is designed to protect the pump only as it is not a safety outlet 4 7 2 Operation principle The pressure by pass valve is located in the rotor case and prevents excess pressure arising inside the pump For example when the pump s discharge port is clogged and the liquid cannot be pumped out too high a pressure can cause serious damage to some of the pump s parts The pressure relief valve opens a passage from the pump s discharge side to its suction side an escape route redirecting the flow again to the suction side whenever specifically high pressure levels are reached The by pass is effective in both directions of rotation only front cover assembly If the relief valve operates this will mean that the equipment is not working properly The pump should be disconnected immediately dentify and solve the problem before re starting the pump A Remember that the pressure relief valve is not able to be used to regulate the flow rate The pressure relief valve can be adjusted to any determined pressure according to the type of pump being used 4 8 ELECTRICAL I NSTALLATI ON Leave the connecting of the electrical motors to qualified personnel Take the necessary measures to prevent any breakdowns in the connections and wires
35. ith the appropriate tightening torque 7 5 4 Assembly of mechanical seals Consult section 7 7 Assembly and disassembly of the mechanical Seals 7 5 5 Lobe assembly ALWAYS check the clearance between the lobes and lobes and rotor case before finishing assembly See 7 6 1 Clearance and tolerance table e Fit new O rings 80 to the lobe screws 25 e Lubricate the rings with soapy water or edible oil compatible with the material of the O rings pumped liquid and application e Fit the shims 32 on the shafts 05 and 05A e See chapter 7 6 3 Lobe Pump Rotor case adjustment using shims e Place the lobes 02 on the shafts 05 and 05A ensuring that the lobe and shaft markings numbers 0 and 1 coincide 0 e Tighten the lobe screws 25 using a spanner In order to prevent the lobes from turning simultaneously blocks of wood or plastic can be placed between the lobes e Assembly is exactly the same for all lobe types 1 2 3 4 7 5 6 Pump cover assembly 22 7 Maintenance ED 2010 09 e Check that the O ring 80A is in good condition or if applicable replace it with a new one e Place it in the pump rotor case 01 ensuring that no dirt or residue of any product remains in the seal or the rotor case If it is necessary to lubricate the O ring to assist in fitting it use soapy water or edible oil compatible with the material of the O ring pumped liquid an application e Place the pump cov
36. ly can rotate in one direction To reverse the direction of the pump s rotation the assembly of the by pass must also be reversed The valve s opening pressure depends on the fluid to be pumped its viscosity its rpm and so before starting up the pump the operator ought to adjust the pressure relief valve s opening pressure working pressure of the pump The end user must adjust the valve to the correct pressure When an overflow valve or a pressure bypass does not operate properly the pump must immediately be removed from service for repair The valve must be examined by the I NOXPA technical assistance personnel When an overflow valve pressure bypass is installed the valve is adjusted to the maximum ED 2010 09 5 Start up 13 _ 5 2 1 External Assembly When installing a pressure relief valve some points shall be considered avoid dead legs e Drainability of the pump and pipeline Please see figure below where recommended installation is shown Wrong Installation Correct installation Example of standard Pressure Relief Valve installation Example of Hygienic NCS Pressure Relief Valve installation with This arrangement creates a dead leg with a large amount actuated rising of product It allows pump and pipeline to drain avoiding dead areas When checking the relief valve also make sure the pump s pressure will NEVER exceed the pressure setting 2 bar When the relief valve d
37. member that there will always be some liquid left in the rotor case if it has not been fitted with a drain Always remember that the liquid that has been pumped may be dangerous or subject to high temperatures For situations of this type please consult the prevailing regulations in the country in question Do not leave loose parts on the floor ALWAYS turn the power supply to the pump off before embarking on maintenance work Take out the fuses and disconnect the wires from the motor terminals gt gt All electrical work must be carried out by duly authorized personnel 1 4 4 In accordance with the instructions Any failure to comply with the instructions could lead to a hazard for the operators the atmospheric conditions of the room and the machine and it could lead to a loss to any right to make a claim for damages Such non compliance could bring with it the following risks e Important operating failures of the machine plant e Failure to comply with specific maintenance and repair procedures Potential electrical mechanical and chemical hazards e Atmospheric conditions in the room could be hazardous due to the release of chemical substances 1 4 5 Warranty We wish to point out that any warranty issued will be null and void and that we are entitled to an indemnity for any civil liability claim for products which might be filed by third parties if e Operation and maintenance work has not been done following the correspondi
38. move the key 61A from the driveshaft 05 Remove the screws 51C and dismount the rear cover 12B while checking that the O ring 80E does not stick to both sides Pumps Size 1 2 3 4 Identify the position of the driveshaft 05 and whether it is in the left or right position Remove the screws 52 the screws 51D at pump size 1 and washers 53A that fix the bearings cover 12 to the gear case 06 Remove the key 61A from the driveshaft 05 Remove the shaft assembly from the gear case Due to the tightness of the bearings cover 12 a Nylon hammer must be used Lightly tap the rear part of the driveshaft 05 Check the condition of the Klingerit seal 18A once the shaft assembly has been removed and if there are any defects find a replacement before reassembling the pump 20 7 Maintenance ED 2010 09 7 5 PUMP ASSEMBLY 7 5 1 Shaft assembly Pumps Size 0 Check that the O ring 80E has not been damaged and attach it with a little grease or oil in the correct position of the bottom cover 12B Attach the rear cover and fix it on with screws 51C Place the key 61A in the driveshaft 05 Pumps Size 1 2 3 4 7 5 2 Filling with lubricant oil Ensure that the Klingerit seal 18A in the case of pump size 4 check the O ring 80E is in good condition or if necessary replace it with a new one and fit it to the gear case 06 Make sure to reassemble the pump wit
39. n 1 i Pusnp sia on a a on oo we ve vet ve ve ve om oe 271 HLR 0 20 73 67 5 227 160 80 20 115 30 5 16 2 14 102 118 9 50 9 65 HLR 0 25 77 280 76 5 230 HLR 1 25 69 289 94 5 222 165 112 25 160 40 6 21 6 19 115 135 9 85 10 105 HLR 1 40 75 301 94 5 228 HLR 2 40 71 338 106 258 200 140 31 190 50 8 27 24 125 150 11 105 12 130 2 50 77 350 106 264 3 50 86 428 133 5 342 280 190 46 5 250 80 10 41 4 38 170 210 13 130 14 170 HLR 3 80 99 450 133 5 355 ED 2010 09 8 Technical Specifications 31 SOURCE OF SOLUTIONS HLR 4 Purp sie da cb ac ea eb ec Jen sp th vo ve val ve ve wn zo ac HLR 4 100 77 8 617 161 5 491 433 225 60 110 16 58 9 55 256 346 18 280 9 320 4 150 104 666 168 517 32 8 Technical Specifications ED 2010 09 8 4 HLR WITH COOLED MECHANICAL SEAL QUENCH DI MENSI ONS HLR 0 25 HLR 1 25 SOURCE OF SOLUTIONS 1 Quench sealing connection 4 x G1 8 ED 2010 09 8 Technical Specifications 33 8 5 O 8 5 1 Exploded view 34 8 Technical Specifications
40. n of same 6 3 General Information ED 2010 09 3 3 1 Field of application P bar 14 1 25 HLR 2 40 ILR 2 50 HLR 3 80 N A SOURCE OF SOLUTIONS HLR 4 150 The range of application for each type of pump is limited The pump was selected for a given set of pumping conditions when the order was placed NOXPA shall not be liable for any damage resulting from the incompleteness of the information provided by the purchaser nature of the fluid rpm ED 2010 09 3 General Information jinas SOURCE OF SOLUTIONS 4 Installation 4 1 PUMP RECEPTI ON INOXPA is not responsible for any deterioration of the material as a result of its transportation or unpacking Visually check that the packing has not suffered any damage The pump will be accompanied by the following documentation Dispatch notes e Pump Instruction and Service Manual e Drive Instruction and Service Manual If the pump has been supplied with a drive from INOXPA Unpack the pump and check the following e The pump suction and delivery connections removing the remains of any packing material da 5 ii Le y Check that the pump and the motor not suffered any D d damage e Should the pump not be in proper condition and or does not have all the parts the haulier must draw up a report as soon as possible with regard to the same 4 11 Pump identification a
41. nd marking INOXPA S A C C Telers 54 BOX 174 17820 BANYOLES GIRONA SPAIN Tel 972 57 52 00 Fax 972 57 55 02 SOURCE OF SOLUTIONS ANO Serial number TIPO KW V Hz QM h Hm RODETE Pump plate 4 2 TRANSPORT AND STORAGE of transport Use the points which are indicated in the drawing for lifting the pump Only authorized personnel should transport the pump Do not work or walk under heavy loads pumps and pumping units are often too heavy to be handled manually Use an adequate means Lift the pump as shown below e Always use two support points placed as far apart as possible e Secure the support so that it will not move See chapter 8 Technical Specifications to consult dimensions and weights 8 4 Installation ED 2010 09 4 3 LOCATION e Position the pump as near as possible to the suction tank and whenever possible below the level of the liquid e Place the pump in such a way that there is enough space around it to provide access both to the same and to the motor See Chapter 8 Technical Specifications to consult dimensions and weights e Place the pump on a level and flat surface e The basement must be rigid horizontal and against any vibration outside it must be done so under cover Its positioning must enable easy access for any inspection Install
42. ng instructions the repairs have not been made by our personnel or have been made without our written authorization e Modifications are made to our material without prior written authorization The parts or lubricants used are not original INOXPA parts lubricants e The material has been improperly used due to error or negligence or has not been used according to the indications and the intended purpose parts of the pump have been damaged as a result of having been exposed to strong pressure as there was pressure relief valve The General Delivery Terms which you have already received are also applicable safety use spare parts and original accessories The use of other parts exempts the manufacturer No modification be made to the machine without the prior consent of the manufacturer For your A from any and all responsibility Any change in operating conditions can only be done with the prior written consent of I NOXPA In the event of doubt or should you require a fuller explanation on particular data adjustment assembly disassembly please do not hesitate to contact us 4 1 Safety ED 2010 09 2 index Safety 1 1 Instr ction Bun EE 1 2 Start up Bin 7 EE RE E 1 4 General safety instructions Index General nformation EECH ee MEER 3 2 Operating Principle EE KE Dee tele EE Installation 4 1 Mese p 4 2 Transport
43. oes not work properly the pump must be taken out of service immediately The valve must be inspected by an I NOXPA service technician 14 5 Start up ED 2010 09 SOURCE OF SOLUTIONS 6 Operating Problems The table given below provides solutions to problems that might arise during pump operation With respect to the same it is assumed that the pump has been properly installed and has been correctly selected for the application in question Should there be a need for technical service please contact INOXPA Operating problems Probable causes Motor Overload 2 16 20 21 22 23 24 26 Insufficient discharge flow rate 4 5 7 8 9 10 11 13 14 No pressure the discharge side 2 3 6 7 Irregular discharge flow rate pressure 4 5 6 9 12 Noise and vibrations 6 7 8 9 11 12 13 16 19 20 21 22 23 24 25 26 The pump gets clogged mus 16 19 20 21 22 24 25 26 Overheating of pump 11 12 16 20 21 22 23 24 26 Abnormal wear Leak through mechanical seal FIBRIN O N NE N 20 LI D GE BIN ui o e 1 15 16 19 24 25 1 Wrong rotation direction Invert the rotation direction 2 Insufficient NPIP Increase available NPIP e Rise the suction tank e Lower the pump e Reduce the speed e Increase the diam
44. r pressure e Another possibility involves long pipes or when a check valve is installed in the discharge pipe it is also possible to install a by pass with a shut off valve on the discharge side of the pump This valve shall be opened in the case of priming and will allow air and gases to escape at a minimum counter pressure e The by pass should not lead back to the intake orifice but to the supply tank instead 10 4 Installation ED 2010 09 4 5 3 Barrier fluid with pressure tank As the HLR Double Mechanical seal is of balanced design the installation of a pressure tank is not necessary Pressure tank is only necessary if the pumped liquid process safety rules requires it Install ALWAYS the pressure tank between 1 and 2 meters above the mechanical seals See the figure below Connect ALWAYS the barrier fluid input connection with the bottom chamber seal connection So the barrier fluid outlet will be carried out by the top chamber connection See the figure below 4 1 Mechanical seal Pressure tank connection lay out To obtain further information about the pressure tank installation operation maintenance consult the instruction manual supplied by the manufacturer 4 6 SECONDARY PI PING 4 6 1 Quench If the seal requires flush media the media supply and the purchase and installation of piping valves for the media are not the responsibility of INOXPA The flush shaft seal option is availa
45. ry from one pump to another SOURCE OF SOLUTIONS ED 2010 09 8 Technical Specifications 37 8 7 HLR 2 8 7 1 Exploded view 38 8 Technical Specifications ED 2010 09 8 7 2 Spare parts list 01 02 03 05 05 06 08 12 12 17 17 17 18 19 19 25 32 35A 45 47A 50 50A 51 51A 52 53 53A 54A 55A 55B 56 56B 61 61A 62 63 65A 66 70 70A 80 80A 80B 82 84 85 86 87 88 89 Rotor case 1 AISI 316L HLR 2 40 short HLR 2 50 large Rotor 2 AISI 316L HLR 2 40 short HLR 2 50 large Front cover 1 AISI 316L Drive shaft 1 AISI 329 Driven shaft 1 AISI 329 Gear case 1 GG 22 Mechanical seal 2 SiC C EPDM Bearing cover 1 GG 22 Bearing stop flange 2 GG 22 Drive shaft bushing 1 ST 52 Driven shaft bushing 1 ST 52 Dragging bushing 1 ST 52 Bearing cover gasket 1 Klingerit Driver shaft gear 1 F 154 Driven shaft gear 1 F 154 Lobe screw 2 AISI 316L HLR 2 40 short HLR 2 50 large Shim 9 55 Seal washer 8 AISI 316L Wing nut 4 AISI 304 Protector 1 PET Plus Screw 2 A2 Countersunk screw 8 A2 Allen screw 8 8 8 Allen screw 6 A2 Hex Screw 4 8 8 Flat washer 4 A2 Grower washer 4 A2 Hexagonal nut 4 A2 Stud 4 A2 Stud 4 A2 Pin 4 F 522 Pin 4 A2 Key 1 F 114 Key 1 AISI 304 Safety nut 2 Steel Safety washer 2 Steel Conical tightening ring 2 Steel Circlip 1 Steel Ball bearings 2 Steel Needle bearings 2 Steel O ring 2 70 EPDM Front cover gasket 1 70 EPDM O ring
46. ssure e Adjust the clearance 23 Coupling misalignment Align the coupling 24 Tension on the pipelines Connect the pipelines to the pump free of tensions 25 Foreign bodies in the liquid Insert a filter in the suction pipe 26 Pump and or electric motor not fixed on Tighten check that the piping has been connected stress foundation free and align the coupling or its representatives If the problem persists use of the pump must cease immediately Contact the pump s manufacturer ED 2010 09 6 Operating Problems 15 SOURCE OF SOLUTIONS 7 Maintenance 7 1 GENERAL MAI NTENANCE This pump as with any other machine needs to be maintained The instructions contained in this manual deal with the identification and replacement of the spare parts These instructions have been drawn up by maintenance staff and are destined for those people who are responsible for supplying spare parts i Read carefully Chapter 8 Technical specifications All the parts or materials that are changed must be duly eliminated recycled in accordance with the prevailing directives in each area A ALWAYS disconnect the pump before starting out on any maintenance work 7 1 1 Check the mechanical seal Periodically check that there are no leaks in the shaft area Should there be any leaks in the mechanical seal area replace the same pursuant to the instructions given in the Pump Disassembly and Assembly sections
47. ted on each shaft If more than one is mounted on each shaft keep them separate to prevent them from getting mixed up Pump size 0 Remove shaft sleeve 13 mounted on each shaft Sleeves are not interchangeable Remember the shaft each sleeve was mounted on 18 7 Maintenance ED 2010 09 7 4 3 Disassembly of mechanical seals As a result of the pump design it is not necessary to disassemble the rotor case 01 in order to assemble disassemble the mechanical seals Rotatory part is directly mounted to lobe housing Stationary part is directly mounted to the rotor case Pump size 0 Due to the compact design Mechanical Seals are mounted on shaft sleeves Consult section 7 7 Assembly and Disassembly of the Mechanical Seals 7 4 4 Rotor case disassembly 7 4 5 Lubrication oil drainage HLR O HLR 1 2 3 4 Pumps Size e Remove the Allen screws 51B that fix the rotor case to the gear case 06 e Remove the rotor case 01 using Nylon hammer if necessary Pumps Size 1 2 3 4 Loosen and remove the nuts 54 that fix the rotor case 01 to the gear case 06 e Remove the rotor case 01 using Nylon hammer if necessary e Place a container underneath the gear case 06 to collect the lubricant oil so that it can be recycled e Remove the drainage plug 87 located to the rear of gear case ED 2010 09 7 Maintenance 19 7 4 6 Shaft assembly removal Pumps Size 0 Re
48. the working surfaces has a defect e Replace the O rings during assembly Pros Description Single mechanical seal uw WA 01 Rotary part St 02 Stationary part PARR RA A NN WA 1 03 O ring Sy ami 2 04 Washer d 2 05 Drive Ring 06 Wave Spring 07 O ring Disassembly Pump size 0 Remove the shaft sleeve 13 mounted on each shaft Sleeves are not interchangeable A Remember the shaft each sleeve was mounted on Pump size 1 2 3 4 Remove the shaft shims 32 mounted on each shaft If more than one is mounted on each shaft keep them separate to prevent them from getting mixed up e Normally the Rotary Assembly 01 remains housed in the lobe rotor during disassembly Remove them carefully e Remove the stationary parts 02 05 from the rotor case bores along Please proceed carefully Assembly Pump size 0 Fit the sleeves 13 on each origin shaft Pump size 1 2 3 4 Fit the shims 32 on each origin shaft Lubricate all the O rings of the mechanical seal with soapy water or oil compatible with the material of the seals pumped liquid and application e Mount the drive ring 05 into the rotor case bore taking care to align it with the 4 seal washer located in the back of the rotor case Fit the stationary part 02 with the drive ring 05 into the rotor case bore ensuring that the pins of the drive ring 05 engage with the biggest slots of stationary part 02
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