IDROPRES · After the complete fitting of the pump and connection of piping, check the alignment...

PUMPS “E”-SERIES

OPERATING AND MAINTENANCE INSTRUCTIONS MANUAL

IDROPRESPompe

Construction and Overhaul

Busto Arsizio (VA)

PAGINA BIANCA

IDROPRES E-series

OPERATING AND INSTRUCTION MANUAL cod.0397

Pumps “E”-series

operating and instruction manual

E-series IDROPRES

4 OPERATING AND INSTRUCTION MANUAL cod.0397

MANUFACTURER AND MACHINE IDENTIFICATION DATA Manufacturer: IDROPRES S.r.l. VIA DEPRETIS 23 21052 BUSTO ARSIZIO (VA) ITALY tel. 0331681044 Fax 0331681147 Machine: PUMP “E”-SERIES Manufacturing Year

VIA DEPRETIS 23 - BUSTO A. (VA)

IDROPRES E-series


GENERAL SAFETY RULES

For safety’s sake following general rules must be read when operating, maintenance and similar actions are carried out.

SAFETY RULES

Safety rules involving danger are stated by symbol:

ACCIDENT PREVENTION RULES The pump, described in this manual, has been manufactured according to “Machinery Directive 89/392/EEC” and following amendments. For safety and health of operators, the responsible person must respect and follow the EEC Community Guidelines and the local rules regarding the working environments. When the machine is running and when it is under repair, persons not involved in the work , must not get near the machine. In any case admittance to production rooms is allowed with qualified persons only. Should the pump be used with dangerous liquids or at high temperature, approach it with the due prudence and follow all prescribed safety rules.

E-series IDROPRES


PUMP MAINTENANCE INFORMATION

USE OF INSTRUCTION MANUAL

Before operating the pump, the officers (responsible persons and operators) must be instructed of “SAFETY RULES” contents, described in this manual.

REMARK The IDROPRES S.r.l. reserves the right to modify the machine due to any construction or commercial reasons without being compelled to bring the instruction manual up-to-date immediately. The pump must be used only for purposes and conditions given at the purchase. Before changing the employment conditions contact our Technicians. IDROPRES S.r.l. assure the pump only for purposes and uses specified at the purchasing moment and they do not accept any responsibility for breaking or damages caused by a wrong and unsuitable utilisation of the pump.

MANUFACTURER’S RESPONSIBILITY The manufacturer takes no responsibility for inconvenient, breaking, accidents, etc. occurred and caused by the un-knowledge and non-fulfilment of the instructions stated in the manual. The manufacturer takes no responsibility for modifications, changes and/or installation of accessories which are not previously authorised.

REPLACEMENT OF SPARE PARTS Only ORIGINAL SPARES, tested and authorised by the manufacturer, must be used.

TECHNICAL ASSISTANCE

Any maintenance operation, repair, etc. must be carried out by SKILLED PERSONAL or by the TECHNICAL ASSISTANCE SERVICE

IDROPRES E-series


INTERVENTION REQUEST For any technical intervention or order of spare parts You are requested to always indicate the data stated on the plate. Any request must be done after having examined the inconvenient and relating causes specifying type and part number. Send the request to: IDROPRES S.r.l. Via DEPRETIS, 23 21052 BUSTO ARSIZIO (Varese) ITALY Tel. 0331 - 681044 Fax 0331 - 681147

GUARANTEE

IDROPRES S.r.l. guarantee their products are free of manufacturing defects and all materials are assured for one (1) year from the date of start-up and however within eighteen (18) months from the shipping date. Should the product sold by IDROPRES S.r.l. result to be defective in manufacturing or materials within the guarantee period under normal operating and maintenance conditions, if returned to the supplier, who will bear the transport fees, the pump will be checked and replaced free of charges. IDROPRES S.r.l. will not be responsible for damages due to unproper use by the buyer, his operators or third persons. No cost for maintenance or spares on site will be supported by IDROPRES if not authorised before. Equipment and accessories purchased from subsuppliers and which are components of IDROPRES products are guaranteed only if guaranteed by original manufacturers or other guarantee if any. THIS IS THE ONLY VALID GUARANTEE OF IDROPRES S.r.l. AND IT REPLACES ANY OTHER EXPRESSED OR AGREED GUARANTEE, WHICH ARE EXCLUDED, INCLUDED ALL MARKETABILITY OR ADAPTABILITY GUARANTEES FOR PARTICULAR PURPOSES.

E-series IDROPRES


GENERAL INDEX • MANUFACTURER AND MACHINE IDENTIFICATION DATA --------------------------------------4

• GENERAL SAFETY RULES -------------------------------------------------------------------------5

SAFETY RULES --------------------------------------------------------------------------------------------------------- 5 ACCIDENT PREVENTION RULES ------------------------------------------------------------------------------------------- 5

• PUMP MAINTENANCE INFORMATION ----------------------------------------------------------6 USE OF INSTRUCTION MANUAL ------------------------------------------------------------------------------------------- 6 REMARK--------------------------------------------------------------------------------------------------------------------------- 6 MANUFACTURER’S RESPONSIBILITY-------------------------------------------------------------------------------------- 6 REPLACEMENT OF SPARE PARTS ----------------------------------------------------------------------------------------- 6 TECHNICAL ASSISTANCE ---------------------------------------------------------------------------------------------------- 6 INTERVENTION REQUEST----------------------------------------------------------------------------------------------------- 7

• GUARANTEE--------------------------------------------------------------------------------------7

• PUMP DESCRIPTION AND GENERAL ARRANGEMENT ---------------------------------------- 10 SPECIAL EXECUTIONS ------------------------------------------------------------------------------------------------------ 11

• TECHNICAL FEATURES ------------------------------------------------------------------------- 11

• FORESEEN AND UNFORESEEN USE OF THE PUMP --------------------------------------------- 12

• HANDLING AND TRANSPORT------------------------------------------------------------------ 13 MACHINE LIFTING ----------------------------------------------------------------------------------------------------------- 13

PUMP WEIGHT ---------------------------------------------------------------------------------------------------------------------------------------- 13

• INSTALLATION --------------------------------------------------------------------------------- 15 INSTALLATION INSTRUCTIONS-------------------------------------------------------------------------------------------- 15

Pump dimensions ----------------------------------------------------------------------------------------------------------------------------------- 15 PUMP INSTALLATION-------------------------------------------------------------------------------------------------------- 16 PIPING CONNECTION ----------------------------------------------------------------------------------------------------- 16

• PUMP DISASSEMBLY AND ASSEMBLY --------------------------------------------------------- 19 DISASSEMBLY------------------------------------------------------------------------------------------------------------------ 19 ASSEMBLY ---------------------------------------------------------------------------------------------------------------------- 20

• PRELIMINARY OPERATIONS BEFORE PUMP STARTING-UP ------------------------------------ 21 ALIGNMENT-------------------------------------------------------------------------------------------------------------------- 21

• PUMP STARTING-UP---------------------------------------------------------------------------- 22 STARTING-UP INSTRUCTIONS--------------------------------------------------------------------------------------------- 22 START-UP------------------------------------------------------------------------------------------------------------------------ 23

• RESIDUAL RISK ANALYSIS---------------------------------------------------------------------- 24 DANGER OF FINGERS ------------------------------------------------------------------------------------------------------ 24 GENERAL RISKS--------------------------------------------------------------------------------------------------------------- 24

REMARK ------------------------------------------------------------------------------------------------------------------------------------------------ 25

• MAINTENANCE AND REPAIR ------------------------------------------------------------------ 26 MAINTENANCE INSTRUCTIONS------------------------------------------------------------------------------------------ 26 AT THE END OF REPAIR WORKS ----------------------------------------------------------------------------------------- 26

IDROPRES E-series


TROUBLE SEARCH------------------------------------------------------------------------------------------------------------ 27 FUNCTION ANOMALIES --------------------------------------------------------------------------------------------------------------------------- 31

• NOISE ------------------------------------------------------------------------------------------ 32

• INSTRUCTIONS FOR FIRES---------------------------------------------------------------------- 32

• INFORMATION FOR OBNOXIOUS SUBSTANCE WASTE DISPOSAL -------------------------- 32

• INFORMATION FOR PUMP DEMOLITION ------------------------------------------------------ 32

• SPARE PARTS ----------------------------------------------------------------------------------- 33

E-series IDROPRES


PUMP DESCRIPTION AND GENERAL ARRANGEMENT

Here under a general description of pumps “E” series. For more details see picture for spare parts stated on relating chapter.

Picture A The pump (pict. A) is composed of a pump body (pos. 1) and a cover (pos. 2) containing all components suitable for a perfect function of the same pump. Inside the pump body, there is the shaft (pos. 3), rotated by a ball bearing (pos. 4) assembled on the relating block (pos. 5). The cover sealing (pos. 2) is assured by gasket pos. 6.

1 5

4

3

2

6

IDROPRES E-series


SPECIAL EXECUTIONS

Picture B

For special purposes, the pump will be shaped as stated in picture B. Outside the pump, you can see the hole for the sealing fluxing or conditioning of sealing area (pos. 7), the connections for instruments (pos. 8) and the holes for the conditioning jacket (pos. 9).

TECHNICAL FEATURES

This instruction book is valid only for standard executions of IDROPRES S.r.l. pumps “E”-series. All particular constructions and alternatives are not considered in this instruction book. For the technical features of the pump you have purchased, consult IDROPRES catalogue or contact directly our Technical Assistance Service.

89

7

E-series IDROPRES


FORESEEN AND UNFORESEEN USE OF THE PUMP

The pump must be used only for the processing and product types for which it has been designed and manufactured. Any other utilisation for processing and types of products is strictly forbidden. The manufacturing Firm declines all responsibility for unauthorised different utilisation. Do not exceed the running values specified at the order and/or agreed at the purchase such as: capacity, rotation speed, pressure and temperature or uses different from those foreseen in this book or in the technical documents given by IDROPRES s.r.l. at the sale moment. The utilisation of the pump under conditions different from those above stated, could bring to abnormal solicitations which the same pump could not hold out and can cause damages to persons, animals or things. The pump utilisation for other purposes must be authorised by the Manufacturer previously. IDROPRES S.r.l. assures a safety running of the pump only if used under conditions specified at the purchase and they do not accept any responsibility for breaking or damages caused by a wrong and unsuitable use of the pump.

IDROPRES E-series


HANDLING AND TRANSPORT CARE DANGER

TRANSPORT, UNLOADING AND ERECTION OF THE MACHINE must be carried out by skilled and authorised persons only.

MACHINE LIFTING

PUMP WEIGHT MIN 20 Kg. MAX. 900 Kg. To know the exact weight of IDROPRES pump you have purchased, contact the manufacturer IDROPRES S.r.l. Sling the pump as stated in the pictures below (with or without motor) and check the ropes are well fixed before lifting it. Be care the pump is well balanced during its lifting. Handle the pump carefully.

E-series IDROPRES


CARE

VERIFY THAT ALL EQUIPMENT MUST NOT SWING TOO MUCH DURING THE LIFTING. IN THIS CASE STOP THE LIFTING MEAN IMMEDIATELY AND WAIT FOR THE ROCKING END BEFORE PROCEEDING WITH LIFTING OPERATION. TAKE ALL UNINVOLVED PERSONS AWAY.

IDROPRES E-series


INSTALLATION

INSTALLATION INSTRUCTIONS

All operations must be carried out by authorised or qualified persons. Carry out the work observing following rules: ⇒ Any pressure inside the chamber must be discharged through the suction or discharging

conducts or other suitable connections. ⇒ The transmission gears must be locked or rendered inoperative, so that they cannot start

during operations on the pump. ⇒ The pumps in touch with dangerous substances have been decontaminated and made

safe. ⇒ Changes or modifications of the products are allowed if approved and authorised by

IDROPRES S.r.l. All modifications or installation of spares not authorised are out of IDROPRES S.r.l. ‘s responsibility.

ATTENTION: During the installation and tests, the pump must be protected against accidental movements. Necessary spaces for work and maintenance operations must be kept free around the pump.

Pump dimensions

This manual is valid only for pumps “E”-series manufactured by IDROPRES S.r.l. Particular construction types and alternatives are not considered in these instructions. For the dimensions of the pump you have purchased, consult the IDROPRES catalogue or contact our Technical Assistance Service.

E-series IDROPRES


PUMP INSTALLATION The pump can be connected directly to the piping. An horizontal position of the pump is suggested for a better running of the same. However, for particular conditions, the pump can be fitted vertically. Place the pump close to the fluid to be pumped, if possible, fit it under the fluid level. Pumps “E”-series are selfpriming but much better are the suction conditions, the best will be the pump performances. The pump must be fitted easily accessible for maintenance and inspection. A suitable space must be foreseen for the removal of big pumps. The sense of rotation determines the suction and delivery connections. To establish the sense of rotation, it is always necessary to look for the end part of the pump shaft. If otherwise stated, the rotation is clockwise, that is with suction connection placed on the right side of the pump. The idle pin, which results to be decentralised on the pump cover, should be placed towards the outlets and at the same distance. After the complete fitting of the pump and connection of piping, check the alignment again. An over-pressure valve must be always foreseen for the pump discharging end.

PIPING CONNECTION The joining pipes must be anchored close to the pump and connected to the same without transmitting any stress. Their weight must not load the pump. According to the plant type and relating pumps, we suggest to install stop devices and interception parts. The piping expansions due to heating effect must be suitably compensated in order to avoid stresses on the pump. However before starting new plants, remind to clean, wash and blow always tank, piping and fittings. Unsuitable suction piping type can cause many pumping problems. The pumping plant should be large and short as much as possible. Before fitting and installing the piping system, take following points in due consideration: 1. Do not use piping smaller than the orifices of the pump connection. 2. Clean the inside part of the piping before the connection. 3. NON RETURN VALVE - When you pump a light fluid with a negative suction, a non-return valve placed at the end of discharge piping or a check valve installed in the first horizontal stretch, will facilitate the pump clutch. Be sure that the check valve is quite big in order to avoid excessive load losses. 4. When you approach an obstacle with the suction or discharge piping, turn around the obstacle instead of passing over, avoiding possible shaping of air-pockets (see pictures of the next page)

IDROPRES E-series


5. Where practicable, place piping inclined in order to avoid possible shaping of air or fluid pockets. Air-pockets inside piping make the pump striking difficult. 6. In case of a discharge piping with long horizontal stretch, keep the horizontal portion below the fluid level if possible. In such a way the piping will be full and the pump has not to move a big quantity of fluid at start-up. This is particularly useful when a check valve is not fitted. 7. When you fit an hot or cold system (the managed fluid has a temperature which is different of the air around the pump) be sure that the possibility of expansion or piping shrinkage is foreseen. Expansion unions in unfixed positions (with support) should be used so that the pump body cannot be distorted or bent. 8. NET FILTER - It is a good rule to foresee a net filter on the suction side of the pump to prevent entry of foreign matters into the pump which could damage it or the motor. The filter net or the hole section must be quite large to avoid excessive pressure drops and, at the same time, quite small to protect the pump. In case you have doubts about the pump dimensions, contact the manufacturer and give him the piping dimensions, the delivery and viscosity as well.

The use of a filter is very important for the first start-up of the system in order to keep it cleaned from welding residuals, incrustations or other foreign matters. 9. If an overpressure valve is not provided on the pump, the fitting of it on the discharge piping is recommended. 10. The pump must not be used to bear piping, the piping weight should be supported by hooks, brackets etc. When you fit the piping to the pump, do not apply stress on the pump body. Springing or pulling pipes towards the pump may cause distortions, possible misalignments and probable quick wear of the pump. Do not use the pump to correct errors of pipe laying or assembly. 11. All pipe couplings must be locked. A pipe mastic or a Teflon tape can be used to avoid any loss. Losses in the

suction piping allowing air suction can cause noise, capacity reduction and damages to the pump. 12. Check again the transmission alignment after the pipes are coupled.

SI

NO

KEEP THE HORIZONTAL STRETCH UNDER HEAD

SI

NO

E-series IDROPRES


13. The auxiliary piping connected to jackets for cooling/heating or other necessities, must be installed with the same care reserved to the pipes for fluid pumping. 14. An overpressure device is to be foreseen for each side of the pump or the piping system possible to be protected by valves, and, therefore, completely insulated. 15. Interception valves on delivery and suction way must be provided in order to allow the maintenance operations or replacement of the pump without causing excessive coming out of the product.

IDROPRES E-series


PUMP DISASSEMBLY AND ASSEMBLY The assembly and disassembly operations must be carried out only by specialised and authorised people. Before carrying out these operations on the pump, please verify: 1. The pressure inside the chambers must be completely discharged through the suction/drain conducts. 2. Switch off the tension of the electric plant connected to the pump and verify that all transmission gears are locked so that they cannot be started when operating on the pump. 3. Pumps used to manage dangerous substances for the operator must be decontaminated.

DISASSEMBLY ATTENTION Mark all components before disassembling them to be sure to effect a correct reassemble of the pump components. 1. Remove the screws of the bearing box pos. 3 and extract it by means of a puller. Clean shaft pos. 6 and remove any product mark and eventual dinges. This is very important to avoid damage to packing elements and to shaft bushing during the disassembly phase. Unscrew the grain and remove the packing gland pos. 18. 2. Unscrew and remove the cover pos. 2 and the idler gear pos. 5 using the suitable extraction holes; pay attention to avoid idler gear can fall. 3. Beat gently on the shaft, drive side, with a plastic hammer, for the extraction of the shaft pos. 6 complete with drive gear pos. 4. 4. Check the satellite bushing pos. 9 and the shaft bushing pos. 8. If the radial play value is not included between 0,05-0,08 mm, it is necessary to replace it. Check also the wear of the idler gear pin pos. 7 and of shaft pos. 6. If there are riffling, replace them.

E-series IDROPRES


ASSEMBLY 1. Insert the wheel and the shaft into the body pos. 6-4, fit the cover pos. 2 without the gasket pos. 11 and idler gear pos. 5. Beat delicately with a pipe on the shaft bushing pos. 8 in order to eliminate the axial play between drive gear and cover. With a drill make a countersink on the shaft bushing inside the grain hole, clean the hole carefully and insert the grain without screwing too much using an hermetic product on the thread (type LOCTITE 542). 2. Remove the cover. Before fitting the cover, it is necessary to take the depth between the drive gear and the pump body (quote A of the drawing below) and verify it is 0,2 mm. equal or less of quote B (cover depth). Use gaskets to reach the operating tolerances. Insert the idler gear and the gasket pos. 11 of thickness from 0,2 to 0,5 mm. according to the viscosity of the pumped product. Lubricate and reassemble.

3. Insert the gland rings alternating the joints. Then fit the packing nut and the bearing block. “IDROPRES S.R.L.” personnel are at your complete disposal for any necessity.

PUMP COVER

PUMP BODY

DRIVE GEAR

-0.3

B A

IDROPRES E-series


PRELIMINARY OPERATIONS BEFORE PUMP STARTING-UP Before pump starting-up, following controls must be carried out in order to avoid any damage.

♦ First of all verify that the pump is not damaged during transport and lifting. • For any doubts about integrity of the pump, equipment and accessories, contact the

manufacturer (see “PLANT MAINTENANCE ASSISTANCE INFORMATION) • Remove the blocking elements put by the carrier in the movable parts • If the pump remains unused for long time and may be subject to atmospheric agents,

remove any possible corrosion with suitable detergent substances (effect disassembly and cleaning).

CAUTION: These substances can be harmful if used improperly, skin-absorbed or ingested; the person charged with this operation must wear mask, protective goggles and gloves. All people charged with maintenance operations must be furnished with necessary protective means. ♦ Fill with fluid to convey the pump and the suction piping. ♦ Open the interception unit in the suction piping. ATTENTION: the pump must not absolutely operate in dry conditions

ALIGNMENT VERIFY THE ALIGNMENT AFTER THE ASSEMBLY. Verify the alignment between motor shaft and pump in order to settle eventual displacement due to transport. 1. Verify the pump connections are perpendicularly and in suitable position; pack the pump if necessary. 2. If the pump is connected to the motor or reducer by means of a flexible hose, remove any protection or cover and verify the alignment of the coupled sections. If the pump is connected by means of a V belt, verify the alignment with a well tensioned rope through the faces of the pulley. 3. Effect a final check after the connection of the piping 4. Reassemble all carters and covers moved for the alignment control.

E-series IDROPRES


PUMP STARTING-UP

STARTING-UP INSTRUCTIONS

The responsible operator of the machine and/or plant where the pump is installed must prevent unauthorised persons from using it.

After the start-up, the pump must not emit unusual noises; in that case it is necessary to stop it and individuate the cause.

BEFORE PRESSING THE PUSH-BUTTON “START-UP” VERIFY WHAT FOLLOWS: 1. On the pressure or vacuum indicators (if any assembled on or near the pump) verify if there are problems on the pump. 2. Verify the coupling alignment. 3. Verify the piping and be sure that there are no stress on the pump body. 4. Turn the pump shaft and verify it rotates freely. 5. Verify all protections are reassembled correctly and fixed safely. 6. Verify all overpressure devices are fitted correctly and without possibility to separate it from the pump. 7. Verify the suction piping and be sure that:

⇒ the same are connected and fixed safely ⇒ valves are open ⇒ the piping outlet is below the fluid level

8. Verify the discharge piping and be sure that:

⇒ the same are connected and fixed safely ⇒ valves are open ⇒ the space for the fluid exit is sufficient

9. For stuffing-box pumps loosen the fixing bolts of the packing nut and adjust them to reduce the product drawing only after the pump has reached the constant temperature. The stuffing-box should draw lightly to keep it lubricated and cooled. 10. Verify all gauges, indicators and other loosen pieces are placed far from moving parts of the pump. Verify the suction and discharge valves are open. 11. Connect the electrical feeding and move the motor to be sure it turns in the correct direction. 12. For high operating temperatures (over 150 °C) await the pump has reached the operating temperature, then check the alignment again. Remind to switch off the electrical feeding before removing the group and be sure it is connected before starting up again.

IDROPRES E-series


START-UP If there is no problem, the pump begins to supply fluid within 60 seconds from the start-up, otherwise press “stop” push-button. Do not turn the pump in dry conditions for more than one minute, otherwise serious damages could occur. Repeat the above mentioned steps for the start-up, check the pressure/discharge indicators and if all is OK fill a little bit of fluid into the pump. A lubricant fluid is suggested to facilitate the primer. Press “start” push-button again. If the pump does not supply fluid within two minutes, stop it again. The pump is not a compressor and it will not accumulate many air pressure. May be it is necessary to air the discharge piping till the fluid begins to flow. If it does not pump, repeat all above steps and if everything is regular contact our assistance service. Follow these prescriptions for a long and safe pump life, after the start-up: ∗ Do not turn the pump at a speed higher to the speed stated in the catalogue for your

model. ∗ Do not expect the pumps supplies pressures higher to those stated in the catalogue for

your model. ∗ Do not start pumps without installed protections. ∗ Do not use pumps without an overpressure valve on the pump or on the discharge piping

and be sure the valve is fitted correctly. The valve inside the pump is only an overpressure valve. It is also requested to fit an external

valve with the same diameter of piping and calibrate it to a pressure lower than the internal one. The use of the inside valve as by-pass can provide an heat accumulation into the pump which could cause dangerous conditions or accidents.

∗ Spare parts or a complete pump must be stocked in warehouse, specially if the pump is

an essential part of a specific process.

E-series IDROPRES


RESIDUAL RISK ANALYSIS

CAUTION - DANGER

READ FOLLOWING CHAPTER BEFORE OPERATING THE PUMP

The described pump has been manufactured according to Safety Rules of European Community, and exactly according to Machinery Directive 89/392/EEC and following amendments. The machine is manufactured considering all risks the Operators can meet and it is equipped with all covers and signals installed in such a way to avoid accidents to Operators during the different working processes. However there are possible residual risks which cannot cause accidents under normal production conditions but we would like to mention to better protect the Operator safety.

DANGER OF FINGERS During the operation it is absolutely forbidden to touch the moving parts. Anyway before operating on the pump, stop the machine where it is fitted and switch off the master switch. FOR NO REASON, DO NEVER APPROACH THE PUMP IN FUNCTION. Do not introduce fingers into the pump connections. The rotating parts could cut if the pump is in function. Do not let the idler gear rotates idle on the pin. Your fingers could be nipped between the teeth and the cover (this can occur only with dismounted pump) ANYWAY DO NEVER OPEN COVERS WITH PUMP IN FUNCTION.

GENERAL RISKS IDROPRES pump is a volumetric pump. This means that when the pump is in motion, the fluid is fed to the discharge side, and in case the discharge pipe is blocked or closed, serious problems could occur to the same pump or to the plant. In fact the motor could stall, the transmission could break and also a pump part can break and piping could explode. In order to avoid and prevent these events, the use of an overpressure valve or an other overpressure device is ESSENTIAL. An overpressure valve reduces the pressure to a set value protecting the whole plant. The over pressure valve assembled on IDROPRES pump and most of the valves on the line are preloaded spring type.

IDROPRES E-series


CAUTIONS The over-pressure valve, internal type, fitted on IDROPRES pumps should have the cover turned towards the suction side of the pump. The valve fitted internally, spring preloaded, is of differential type, feeling the pressures only on the both side of the piston: It is designed as over-pressure valve (see paragraph “START-UP”). The pressure acting the internal over-pressure valve can be modified by the adjusting valve. Electric motors. For the connection of electric motors, follow the local rules in force, Be sure the phases are correct in order to grant the correct rotation direction.

REMARK The pump does not present remarkable residual risks under normal working conditions. Dangerous situations can occur due to Operator’s imprudence or unwillingness to keep out of danger.

E-series IDROPRES


MAINTENANCE AND REPAIR

MAINTENANCE INSTRUCTIONS

Use, maintenance and repairs of the pump are allowed to operators charged by the responsible of the plant who must know the contents of Instruction Manual. All control, adjustment, maintenance and lubrication operations must be carried out with MACHINE OUT OF SERVICE, POWER OFF and EMERGENCY STOP PUSH-BUTTON ON. For operations requiring power “ON” be careful and employ SKILLED PERSONNEL. Turn on the power only for strictly necessary time and with greatest care for persons and machine. Remind that some easy maintenance operations like a periodical lubrication, examination of internal parts, etc. will extend the working life of the pump. Use original spares only, otherwise the main safety features of the pump cannot be assured. Check no residual pressure is inside the pump or in piping. In case the pump is still hooked to the transmission during the maintenance operations, be sure the transmission is locked so that it cannot be started inadvertently while working on the pump. Do not let parts fall during the disassembly, i.e. the idler gear can slide from the pin when the cover is detached from the pump, it could scratch or be notched, Do not let the idler gear rotates idle on the pin. Your fingers could be nipped between the teeth and the cover.

AT THE END OF REPAIR WORKS before machine starting up

The plant responsible must verify that all works are finished, all safety devices are in function regularly and all unemployed persons are get out of the plant.

IDROPRES E-series


TROUBLE SEARCH

Here below we explain how to read the instruments fitted on delivery and suction line of the pump.

Indications of the Pressure gauge on delivery line.

An high reading can indicate:

⇒ the interception valve is partially open; ⇒ an high viscosity or small and/or long delivery line; ⇒ the filter on delivery line can be obstructed; ⇒ a too high calibration of the safety valve; ⇒ the delivery piping can be obstructed; ⇒ the pumped fluid is not at operating temperature; ⇒ an high specific weight not considered; ⇒ the fluid inside the piping can be solidified;

A low reading can indicate: ⇒ by-pass on line is partially open; ⇒ the safety valve does not function properly; ⇒ the pump can have too high internal clearances; ⇒ the safety valve is calibrated at a too low value; ⇒ the pump can be worn-out;

A floating reading can indicate: ⇒ the pump is in cavitation; ⇒ the fluid reaches the pump in intermittent way; ⇒ air could enter in suction line; ⇒ some vibrations can be caused by a wrong alignment or by mechanical troubles.

E-series IDROPRES


Indications of the vacuum gauge on suction line

An high reading can indicate:

⇒ the fluid is too viscous to slide inside the piping; ⇒ the suction is too high; ⇒ the suction is blocked; ⇒ the foot valve is stuck; ⇒ the interception valve is closed; ⇒ the filter is clogged;

A low reading can indicate:

⇒ the end of the suction pipe does not suck the fluid; ⇒ air has come into piping; ⇒ the pump is worn-out;

An erratic, floating, spring reading can indicate: ⇒ the pump is not primed; ⇒ the fluid evaporates; ⇒ the suction is not enough; ⇒ discontinuous arrival of the fluid to the pump.

IDROPRES E-series


Here under you will find general solutions suggested for some problems that may occur:

1. The pump absorbs too much power.

♦ It turns faster than that foreseen. Check motor, reducer, pulleys etc. ♦ Viscosity higher than foreseen. Increase the diameters of the piping, reduce the revolutions,

more powerful motor. ♦ Delivery pressures higher than foreseen. Check with a pressure gauge. Increase the diameter

of the delivery piping. Reduce the revolutions, bigger motor. ♦ Too narrow stuffing box. ♦ Off centre pump. ♦ Insufficient internal clearances inside the pump for the operating conditions. Increase the

tolerances.

2. Early wear of the pump.

♦ Generally it takes months or years before the pump decreases its performances. The wear is generally equally distributed. When the wear is early, the wear presents deep rulings, too polished parts, uneven consumption.

3. The pump does not pump.

♦ Interrupted priming. Air inlet inside the suction piping. Low fluid level in the tank, bottom vale

stuck. ♦ Too elevate suction. ♦ Wrong rotation direction. ♦ The motor does not reach the foreseen speed. ♦ Interception valves on suction or delivery line, are closed. ♦ Clogged filter on suction line. ♦ By-pass valve is open, safety valve is open. ♦ The pump is worn-out. ♦ Changes in the system such as additional tanks, new suction lines, unskilled operators, etc. ♦ Too much clearance between rotor and cover. ♦ Cover placed incorrectly.

E-series IDROPRES


4. The pump starts and then it not primes.

♦ Empty tank. ♦ Fluid evaporated in the suction line. ♦ Air inlet in the suction or sealing line. ♦ The pump is worn-out.

5. The pump makes noise.

♦ The pump does not receive sufficient fluid. Increase the diameter of the suction piping or

reduce its length. ♦ The pump hollows (the suction fluid evaporates) Increase the diameter of the suction piping

or reduce its length, increase the positive shutter or reduce the negative one. ♦ Defective alignment. Check it. ♦ Shaft or rotor tooth is bent. Straighten it, or better, replace it. ♦ The safety valve makes noise. Increase the calibration pressure. ♦ Anchor the baseplate or pipes to reduce vibrations.

6. Output lower than what foreseen

♦ Lack of feeding or pump is in cavitation. ♦ Filter partially clogged. ♦ Air coming in suction or from sealing. ♦ Motor turns slowly than foreseen. Check motor and reducer. ♦ By-pass line partially open ♦ Safety valve calibrated too low or remained open. ♦ The pump is worn out. ♦ Reduce clearance between cover and rotors.

IDROPRES E-series


FUNCTION ANOMALIES

TROUBLE

CAUSE

REMEDY

Abrasion

Scratches or deep signs caused by big and hard particles, Early consumption of bushes and pin.

Remove the pump from the circuit, Apply a filter on suction line. Sometimes it is necessary to repeat this operation before cleaning the circuit. .

Corrosion

Rust, metal attached on wide surfaces, metal scales or decays.

Check if the used materials are suitable and the several metals are corrosive in the same manner. Check if the fluid has not been polluted and made more corrosive by the presence of other fluids not foreseen. .

Function under conditions higher than those foreseen in the catalogue.

Noise, broken bushes, bent shafts, parts show to have got too warm.

Check the pump runs within the limits foreseen for this particular model.

Insufficient clearances

The pump can block. Seizing-up signs among rotor, body and head.

Increase the clearances or contact the suppliers to ask for information.

Cross-axing

Consumption on one side only such as body, stuffing box and head.

Check the unit alignment and piping does not stress the pump.

Dry function

The pump blocks, seizing-up of the parts in touch, sealing seats and pins change colour due to excessive heating.

Be sure the fluid arrives to the pump. Put levels in the tanks.

E-series IDROPRES


NOISE The pump, normally used and correctly installed, does not cause high noise, If this occurs stop the pump immediately because this means that there is an anomaly inside the pump or in the plant connected to it. High noise is often caused by pump in cavitation.

INSTRUCTIONS FOR FIRES Usually the pump is not subject to fires. Fires can occur due to treated products and used fuels Observation of fire prevention rules in force is compulsory. Before using dangerous fluid, verify with our assistance service that the pump can be used for this purpose.

INFORMATION FOR OBNOXIOUS SUBSTANCE WASTE DISPOSAL Conform to EEC prescriptions and local rules in force.

INFORMATION FOR PUMP DEMOLITION The pump demolition produces ferrous wastes only. It is sufficient to follow CEE prescriptions and local rules in force regarding the getting rid of unobnoxous wastes.

IDROPRES E-series


SPARE PARTS

SEZIONE A BADERNAPacking pump section

Pos. Descrizione Description

1 5

2

3

4

7

118 17 18 12 10

11

6

13

16

PARTICOLARE TEN.MECCANICA

PARTICOLARE Anelli Ten. LIP

22

21

20

25

26

24

19

6

9

Radial seal detail

Mechanical seal detail

1234567891011121316

1819202122

2524

Corpo pompa Coperchio pompaSupporto cuscinettoRuota comandoSatelliteAlbero (ceramizzato in vers. LIP)

Boccola albero Boccola satelliteCuscinetto a sfere

Nilos

SeegerChiavetta

BadernaPremitreccia

Guarnizione corpo

Distanziali anelli tenutaPressello

Seeger tenuta meccanica

Anello rotante tenuta meccanicaAnello fisso tenuta meccanicaAlloggiamento tenuta meccanica

Anelli tenuta LIP

Perno Satellite

17

26

Casing pumpPump coverBearing supportGear driveIdler gearShaft (ceramized in LIP Version)Idler gear pinShaft bushingIdler gear bushingBall bearingCasing gasketSeegerKeyNilos ringPackingPacking glandMechanical seal seegerSeal holder plateStationary seat ringMechanical seal rotary ringPacking nutSeal ring washerSeal ring LIP type

E-series IDROPRES


Valvola di sicurezza a mollaRegolabileSafety spring valveAdjustable

Esecuzione StandardTenuta meccanica semplice

Standard ExecutionSimple Mechanical Seal

Esecuzione TandemTenuta meccanica doppia in tandem

Tandem ExecutionDouble Tandem Mechanical Seal

Esecuzione CombinataTen.meccanica con abbinato liquido di sbarramento

Combined ExecutionMechanical Seal joined with liquid barrage

Pos.12345678910

1

10

5

3 4 962 7 8

DescrizioneCorpo By-PassCoperchietto By-PassValvolaPiattelloMolla

Guarnizione dadoGuarn.Coperchietto

Vite regolazioneDado BloccaggioCoperchio regolazioneBy-Pass completo

DescriptionBy-Pass BodyBy-Pass coverValvePlateSpringTuning screwBlocking nutTuning coverCasing nutCasing cover

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IDROPRES · After the complete fitting of the pump and connection of piping, check the alignment...

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Transcript of IDROPRES · After the complete fitting of the pump and connection of piping, check the alignment...