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Alfa Laval ALP 100, Operating Instructions Manual

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Alfa Laval ALP 100 Operating Instructions Manual Download Page 1

Screw pumps ALP Sizes 0100–0280 Magnetic
coupling M-type

Operating Instructions

BRITISH ENGLISH

Lit. Code

200007725-1-EN-GB

Manual No.

9062571 02

Component Description

Summary of Contents for ALP 100

Page 1: ...Screw pumps ALP Sizes 0100 0280 Magnetic coupling M type Operating Instructions BRITISH ENGLISH Lit Code 200007725 1 EN GB Manual No 9062571 02 Component Description...

Page 2: ...ned by Alfa Laval Corporate AB No part of this document may be copied re produced or transmitted in any form or by any means or for any purpose without Alfa Laval Corporate AB s prior express written...

Page 3: ...5 Technical data 17 5 1 Operating limits 17 5 2 Required NPSH values 18 5 3 Weights 19 5 4 Dimensions 20 5 5 Capacity tables 22 5 6 Noise levels 23 5 7 Overflow valve 23 5 8 Materials 23 6 Function de...

Page 4: ...he pump 44 9 7 Taking pump out of operation 45 9 8 Recommissioning the pump 46 10 Maintenance 47 10 1 Safety instructions on maintenance and repairs 47 10 2 Required maintenance 48 10 3 Magnetic coupl...

Page 5: ...9 12 3 Tensioning element 70 12 4 Valve body cone 70 12 5 Cylindrical spring 70 12 6 Containment can 70 12 7 Screw plug for ALP magnetic coupling 71 13 Appendix 73 13 1 General drawings 73 13 2 Parts...

Page 6: ......

Page 7: ...hazardous situation which if not avoided will result in death or serious injury WARNING WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injur...

Page 8: ...200007725 1 EN GB 8 1 Warning signs in text EN Safety...

Page 9: ...lations Specialist personnel fitters Read observe and follow these instructions and the associated docu ments in particular the safety instructions and warnings 2 3 Symbols Symbol Meaning Procedures m...

Page 10: ...200007725 1 EN GB 10 2 About this document EN...

Page 11: ...at does not agree with the specifications on the rating plate please contact the manufacturer The pump is specifically configured for the operating pressure stated by the customer In the case of a sig...

Page 12: ...regulations for the prevention of accidents as well as the local safety and operating instructions Observe the valid national and international standards and specifications of the installation locatio...

Page 13: ...ances may persons with pacemakers perform installation dismantling or maintenance work Persons with pacemakers must comply with the following safe distances to the MCS 3 m distance to the openly acces...

Page 14: ...200007725 1 EN GB 14 3 Safety EN Safety...

Page 15: ...l 2022 M Magnetic coupling From May 2022 4 Overflow valve Opening at differential pressure bar A 6 10 B 10 10 5 Completion A Pump with free shaft end B Pump unit for vertical mounting with pump bracke...

Page 16: ...4 2 Communication plate Figure 2 Rating plate 1 Pump type 2 Serial number 3 Year of contructions 4 Item number 5 Temperature max 6 Differential pressure max 200007725 1 EN GB 16 4 Labelling EN...

Page 17: ...w valve B Differential pressure max bar 5 4 9 End pressure max bar 16 16 Valve opening pressure bar 6 10 10 10 Temperature max C 155 155 Temperature min C for pump materials 20 20 Viscosity min max mm...

Page 18: ...doubt please contact the manufacturer Table 3 Required NPSH values Size Viscosity mm2 s NPSH value mWC Rotation speed min 1 Size Viscosity mm2 s NPSH value mWC Rotation speed min 1 1450 1750 2900 350...

Page 19: ...no 23 0 6 7 29 7 yes 7 8 30 8 ALP 0115 132 30 Nm no 23 0 6 7 29 7 yes 7 8 30 8 ALP 0165 132 60 Nm no 38 3 9 1 47 4 yes 10 2 48 5 160 60 Nm no 38 3 11 6 49 9 yes 14 0 52 3 ALP 215 160 60 Nm no 38 3 11...

Page 20: ...10 180 11 100 112 75 30 272 5 148 60 97 39 21 178 15 132 250 220 13 132 75 40 272 5 196 80 116 40 20 205 18 160 290 260 13 165 215 100 112 75 40 333 5 175 60 97 39 21 216 15 132 250 220 13 132 75 60 3...

Page 21: ...200007725 1 EN GB 21 Technical data 5 EN...

Page 22: ...4 165 4 165 8 166 5 167 3 Table 8 Capacity at 60 Hz p 4 bar Size Rotation speed vmax Motor Delivery rate l min at viscosity mm2 s min 1 mm2 s kW 13 30 40 60 100 180 380 460 700 1200 ALP 100 3400 150...

Page 23: ...t circuit pressure bar at rotation speed min 1 Overflow valve A Overflow valve B 1450 1750 2900 3500 1450 1750 2900 3500 100 115 7 5 8 0 9 0 10 0 12 0 12 5 13 0 14 0 165 215 8 0 8 5 10 0 11 0 13 0 13...

Page 24: ...200007725 1 EN GB 24 5 Technical data EN...

Page 25: ...placement effect results from the meshing of three rotating screws and the enclosing housing The radial support of the screws is effected by the sliding contact in the housing which requires lubricati...

Page 26: ...rotor The pressure discharge of the containment can approximately corresponds to the pressure on the suction side of the pump 6 3 Overflow valve The integrated overflow valve prevents very high pressu...

Page 27: ...the pump pump unit Figure 5 Attachment of hoisting equipment schematic diagrams DANGER Risk of injury and or damage to equipment should the pump pump unit fall Use intact and correctly dimensioned hoi...

Page 28: ...components of the pump are preserved with a single coat PU based two component paint The preservative applied at the factory will protect the pump for about six weeks if it is stored in a dry and clea...

Page 29: ...hes approx 2 cm under the pressure flange while slowly turning the main screw against the direction of rotation 3 Close the pressure connection of the pump with a blind flange After about 6 months sto...

Page 30: ...he pump Collect the emitted oil safely and dispose of it in an environmentally compatible manner 1 Clean the outside of the pump with solvents if necessary using a steam jet cleaning device 2 Remove t...

Page 31: ...e discharging pumped liquid and oil and dispose of it in accordance with the locally applicable regulations Neutralize any residues of the pumped liquid 1 Disassemble the pump 2 Clean residues of the...

Page 32: ...200007725 1 EN GB 32 7 Transportation Storage and Disposal EN...

Page 33: ...nstallation removal or connection work 8 2 Installation NOTE Observe the following instructions When selecting the location take the operating limits NPSH values and ambient conditions into account re...

Page 34: ...using the protective covers mounted in the factory CAUTION Leaking pumped liquid can damage the motor Do not mount the pump above the motor CAUTION Damage to the pump and piping through insufficient...

Page 35: ...the pipe system and the pump After the connecting work carefully clean the pipe system refer to 8 4 1 Connecting the pump to the pipe system Figure 8 Wrong installation Figure 9 Correct installation...

Page 36: ...ure sign that the installation is stress free 5 Tighten the connecting screws crosswise with torque 8 4 2 Connecting the motor DANGER Risk of death resulting from electric shock The motor may only be...

Page 37: ...to the ambient temperature Ensure that the pump is depressurized Collect the pumped liquid safely and dispose of it in an environmentally compatible manner 1 Disconnect the motors from the power supp...

Page 38: ...200007725 1 EN GB 38 8 Installation removal and connection EN...

Page 39: ...risk of death for people with pacemakers Under no circumstances may persons with pacemakers perform commissioning work CAUTION The following instructions must always be observed 1 The pump may only b...

Page 40: ...er has to be installed before the pump Mesh width of the commissioning filter 0 025 mm CAUTION Damage to the pump through additional pressure loss in the commissioning filter 1 Calculate the flow resi...

Page 41: ...pump 1 Pumped liquid already exists at the suction or pressure side filling via suction or pressure connection Figure 10 Filling the pump 2 There is no pumped liquid at the suction or pressure side f...

Page 42: ...ction or pressure side shut off device and fill the pump via the suction or pressure connection until pumped liquid is emitted at the vent hole 3 During the filling process turn the pump shaft or the...

Page 43: ...n clockwise as seen from the drive Figure 11 Identifying direction of rotation and flow direction CAUTION Dry running can damage pump equipment Ensure that the pump is filled properly Switch the pump...

Page 44: ...nsure that the pump is filled In case of doubt pre lubricate the pump by pouring in liquid via the vent hole refer to Filling the pump on page 41 2 Switch on the pump The pump will deliver when the pr...

Page 45: ...s from the power supply and secure them against being switched back on Stored Observe measures for storing preservation refer to unique_55 and refer to unique_56 Table 14 Measures depending on behavio...

Page 46: ...9 8 Recommissioning the pump Carry out all the steps as for the commissioning process Refer to Commissioning on page 39 200007725 1 EN GB 46 9 Operation EN...

Page 47: ...work All the work may only be carried out by authorized qualified personnel Wear protective clothing during all the work Switch off the motor and secure it against being switched back on Before begin...

Page 48: ...e table above and eliminate the cause 10 3 Magnetic coupling The shaft end of the pump is enclosed by a containment can that is connected air tight with the motor side flange of the pump Special rotor...

Page 49: ...ption 001 Pump 515 Outer rotor 914 3 Socket screw 053 Coupling hub 529 Motor 914 5 Socket screw 180 Pump bracket 884 Threaded pin A Mounting lever Recommendations Wrench Mounting lever DANGER Risk of...

Page 50: ...s 2 Loosen the connecting screws 914 3 between the motor 529 and pump bracket 180 and lift the pump with pump bracket from the motor 3 Loosen the threaded pin 884 Pull the coupling hub 053 and outer r...

Page 51: ...4 Loosen the socket screws 914 5 between the coupling hub 053 and the outer rotor 515 200007725 1 EN GB 51 Maintenance 10 EN...

Page 52: ...ntainment can 518 Inner rotor B Anti rotation screw 110 Centring flange 914 2 Socket screw C Allen key 180 Pump bracket 914 6 Socket screw Recommendations Anti rotation screw Allen key 1 Loosen the so...

Page 53: ...containment can 3 To replace the inner rotor 518 insert two anti rotation screws B into the empty threaded holes of the tensioning element to prevent rotation Then loosen the screws of the tensioning...

Page 54: ...re 14 Sectional view magnetic coupling Ref Description Ref Description Ref Description 038 Containment can 518 Inner rotor 914 2 Socket screws 040 Distance sleeve 585 Tensioning element 914 6 Socket s...

Page 55: ...he tensioning element 585 slightly NOTE Use only oil without molybdenum sulphide additive eg Multifunctional spray WD 40 3 Turn out the screws of the tensioning element a few turns by hand Insert the...

Page 56: ...ng element with half the tightening torque crosswise Subsequently tighten them several times crosswise with the full tightening torque until no screw can be turned any further NOTE The screws are only...

Page 57: ...8 Place the pump bracket 180 on the pump and tighten the socket screws 914 2 200007725 1 EN GB 57 Maintenance 10 EN...

Page 58: ...Threaded pin 1 Carefully clean the outer rotor 515 with compressed air Tighten the connecting screws 914 5 of the outer rotor and coupling hub 053 with torque 2 Clean the shaft end of the motor and a...

Page 59: ...mp bracket on the motor Do not use force and ensure that the outer rotor does not strike the containment can 6 Tighten the connecting screws 914 3 of the motor and pump bracket Do not remove the prote...

Page 60: ...ion 056 Supporting ring 472 Circlip A Disassembly tool 165 1 Screw plug 817 Ball bearing B Open end wrench 471 2 Circlip 868 Supporting ring C Extractor Only for sizes 100 115 Recommendations Disassem...

Page 61: ...The main screw will be pressed out of the pump housing Remove the main screw from the pump housing 3 Remove the circlip 471 2 and supporting ring 056 4 Pull the ball bearing 817 from the main screw us...

Page 62: ...surfaces and the main screw Grease the main screw slightly 2 Push the supporting ring 868 onto the main screw press the ball bearing 817 onto the main screw 3 Mount the supporting ring 056 and circli...

Page 63: ...ses and measures for elimination Fault Cause Remedy No pump suction 1 2 3 4 5 6 7 8 28 Delivery rate too low 2 3 4 9 10 11 12 13 14 15 16 17 Pump runs noisily 2 3 4 6 10 11 13 15 18 19 20 21 Motor ove...

Page 64: ...at the direction of pump rotation matches that of the arrow on the flange cov er 9 Differential pressure too high Check the system and reduce the differential pressure 10 Magnetic coupling broken off...

Page 65: ...ing If necessary re place pump with free shaft end 23 Thermal or chemical loading of elas tomer seals exceeded Check the maximum operating temperature Check the resistance of the elastomers with regar...

Page 66: ...200007725 1 EN GB 66 11 Troubleshooting EN...

Page 67: ...12 Spare Parts 12 1 ALP magnetic coupling spare parts Figure 18 ALP 0100 0280 spare parts general drawing 200007725 1 EN GB 67 EN...

Page 68: ...nation Qty Dimensions Pos no Maintenance kit MAG 9014380 83 1 Distance sleeve 1 D 20 5xD 25 0x9 5lg 040 Supporting ring 1 S 20x28x2 0 056 1 Supporting ring 1 S 42x52x2 5 056 2 Flat gasket 1 SIL C 4400...

Page 69: ...ce kit MAG 9014380 84 1 Distance sleeve 1 D 30 3xD 52 0x11 0lg 040 Supporting ring 1 S 30x42x2 5 056 Flat gasket 1 SIL C 4400 222 Circlip 1 30x1 50 471 2 Circlip 1 72x2 50 472 O ring 1 105 00x2 50 739...

Page 70: ...0115 Magnetic coupling 9012877 03 1 ALP 0165 0280 Magnetic coupling 9012877 04 1 12 5 Cylindrical spring Cylindrical spring Pos 501 Pump type Part no Qty ALP 0100 0115 Magnetic coupling 9014370 06 1 A...

Page 71: ...lug Table 19 Screw plug for ALP magnetic coupling Pump type ALP MAG Screw plug Part no Pos no 0100 0115 DVV 38 9046911 01 165 1 DVV 36 9046911 02 165 2 0165 0215 0230 0280 DVV 38 9046911 01 165 1 DVV...

Page 72: ...200007725 1 EN GB 72 12 Spare Parts EN...

Page 73: ...13 Appendix 13 1 General drawings Figure 22 ALP 0100 0280 Figure 23 Completion magnetic coupling ALP 0100 0280 200007725 1 EN GB 73 EN...

Page 74: ...e body 471 1 Circlip 471 2 Circlip 472 Circlip 501 Spring 515 Outer rotor 518 Inner rotor 526 Pump bracket foot 529 Motor 585 Tensioning element 661 Screw set In case of wear of the screw set we recom...

Page 75: ...8 0 4 8 6 0 3 9 3 5 4 7 G 3 8 60 9 5 14 7 6 10 3 6 9 6 8 G 1 2 80 23 1 34 18 4 25 17 16 22 G 3 4 120 46 68 36 8 47 33 32 43 G 1 200 80 117 64 84 56 56 75 G 1 1 4 400 127 186 101 133 89 G 1 1 2 450 M...

Page 76: ...Required tool for maintenance work Figure 24 Disassembly tool Table 23 Disassembly tool dimensions Disassembly tool dimensions mm Size d1 l1 l2 s 100 280 G 1 2 130 15 17 200007725 1 EN GB 76 13 Append...

Page 77: ...14 EC Declaration of conformity 200007725 1 EN GB 77 EN...

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