Alfa Laval DuraCirc Range Instruction Manual Download Page 1

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Alfa Laval DuraCirc® Range

Circumferential Piston Pump

BRITISH ENGLISH

3206-0000

Lit. Code

200002348-1-EN-GB

Manual No.

100003046

Instruction Manual

Summary of Contents for DuraCirc Range

Page 1: ...Alfa Laval DuraCirc Range Circumferential Piston Pump BRITISH ENGLISH 3206 0000 Lit Code 200002348 1 EN GB Manual No 100003046 Instruction Manual...

Page 2: ...y 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 permi...

Page 3: ...information 14 4 3 System design installation and operation 15 4 4 Flushing seal arrangement and pre start up checks 21 5 Maintenance 23 5 1 Cleaning in place CIP 23 5 2 Maintenance schedule 25 5 3 D...

Page 4: ......

Page 5: ...32 33 34 42 43 52 53 54 62 63 72 73 74 Type From serial number E10 000 to E1 000 000 is in conformity with the following directive with amendments Machinery Directive 2006 42 EC The person authorised...

Page 6: ...3 72 73 74 Type From serial number E10 000 to E1 000 000 is in conformity with the following directive with amendments Supply of Machinery Safety Regulations 2008 SI 2008 1597 The person authorised to...

Page 7: ...should be specified when ordering but the alternative foot design allows pumps that are already installed being changed should the need arise Drawing shows only mounted unit 3206 0001 D C G B A F E H...

Page 8: ...necessary Vibration Limits Bare shaft pump units have been tested and found to be within the limits published under ISO 10816 7 Category 2 under normal operation conditions Actual vibration of mounte...

Page 9: ...r the task to be carried out or for the information needed This is the complete manual for the supplied product Skills for personal Operators The operators shall read and understand the instruction ma...

Page 10: ...3 2 Warning signs General warning Dangerous electrical voltage Caustic agents Hot Surfaces 200002348 1 EN GB 10 3 Safety EN...

Page 11: ...n place and in good condition Never touch the pump or the pipelines when pumping hot liquids or when sterilising In certain operating conditions the external surface of the pump and or ancillary equip...

Page 12: ...ssories of any liquid Always ensure that no leakage of lubricants can occur Always transport the pump in its upright position Always ensure that the unit is securely fixed during transportation Always...

Page 13: ...ithin the load limits Refer to the pump weights guide Always ensure that the lifting points are in line with the centre of gravity and adjust lifting point if necessary Always keep an eye on the load...

Page 14: ...rrosive substances including those contained in the air Rotate the pump pump unit by hand weekly to prevent bearing damage All associated ancillary equipment should be treated similarly 4 2 Recycling...

Page 15: ...c purposes Fit valves it two pumps are to be used on manifold common discharge lines Make the necessary piping arrangements if flushing is required for the seal Allow at least 1 m for pump access main...

Page 16: ...115 85 170 125 50mm 2 N Ibf 295 66 420 94 Nm Ibf ft 145 107 210 155 65mm 2 5 N Ibf 360 81 510 115 Nm Ibf ft 180 133 263 194 80mm 3 N Ibf 425 96 600 135 Nm Ibf ft 215 159 315 232 100mm 4 N Ibf 505 114...

Page 17: ...oil as standard Oil level must be checked with the pump static using the oil sight glass fitted to the side of the gearbox The oil should be changed every 3000 hrs of operation or every 2 years whiche...

Page 18: ...s of anchoring the baseplate to the foundation are varied they can be studs embedded in the concrete either at the pouring stage as shown below or by use of epoxy type grouts Alternatively mechanical...

Page 19: ...tor shaft misalignment and pump motor unit damage Once the baseplate has been secured the pump shaft to motor shaft coupling alignment should be checked and adjusted as necessary This is achieved by c...

Page 20: ...4 mm 180 0 4 mm 230 0 5 mm 280 0 5 mm Angular Misalignment Measure 4 positions at 90 around coupling Coupling size Dimension A Maximum 3206 0013 B o 70 1 90 1 110 1 130 1 150 1 180 1 230 1 280 1 Assem...

Page 21: ...ff at the same time after stopping the pump A Flush inlet B Flush outlet C Link pipe A B 3206 0015 C 2 Connecting the flush The following equipment is strongly recommended when using a flushing system...

Page 22: ...Flow Limits Single Mechanical Flushed 0 5 bar max Double Seal SiC Carbon 1 bar above pump discharge upto 16 bar max Double Seal SiC SiC 1 bar above pump discharge upto 20 bar max O Ring Seal Flushed 0...

Page 23: ...there are very small clearances can allow contact between the rotating and static parts potentially causing surface damage and pump seizure To minimise the risk of thermal shock occurring it is recom...

Page 24: ...l to AISI 300 Series Stainless Steel However ASTM A 494 has limited resistance to certain aggressive chemicals that may be commonly used in contact with AISI 300 Series Stainless Steel Nitric Acid is...

Page 25: ...or covers especially if this leads to a deterioration of safety performance shall be replaced immediately The fixings of any guards or covers should only be replaced with fixings of the same type and...

Page 26: ...the shaft 2 Submerge and soak nut for 5 minutes in COP tank with 2 caustic wash 3 Scrub the hole with internal thread vigorously by plunging a clean sanitary bristle pipe brush in and out of the hole...

Page 27: ...ont cover P ring 5 NOTE Pump models 62 to 74 are supplied with a M6 tapped hole in the front cover for use with a lifting eye not supplied to aid lifting 3206 0019 3206 0057 2 Removing rotors 1 Insert...

Page 28: ...him retainer 13 and Shims 12 should not be removed unless rotor clearances require resetting 3206 0021 4 Draining pump lubrication 1 Place a tray under the gearcase to collect the waste lubricating oi...

Page 29: ...is essential to renew the lip seal and o ring prior to reassembly 3206 0023 6 Removing Gearcase Cover 1 Remove drive key 65 and then remove rear cover screws 42 2 Tap the center of the cover to help...

Page 30: ...1 Using a soft mallet gently tap the rear end of each shaft 51 and 52 and remove through the front of the gearcase 31 2 Support each shaft during removal from the gearcase 3 Remove the shaft shims 53...

Page 31: ...y in a press with a tool positively located against the rear bearing inner race 58 as shown and apply pressure to the top of the shaft so that the shaft moves through the bearing Ensure the shaft is s...

Page 32: ...wn and apply pressure to the top of the shaft so that the shaft moves through the bearing and spacer pack 4 Once the first bearing is free remove from the shaft together with the spacer 55 and the out...

Page 33: ...9 F Do not use any form of live flame when heating as this will damage bearings 2 Front Bearings Position shafts 51 and 52 vertically in a vice using soft jaws and apply anti seize compound to the bea...

Page 34: ...cate and tighten the bearing nut 57 whilst at the same time rotating the bearings 54 and spacer 55 The bearings are correctly adjusted when the spacer can only be moved with a light tap of a mallet 4...

Page 35: ...32 to 43 on the shaft as shown ensuring a positive fit against the shaft shoulder using a press and appropriate tool if required 3206 0029 DuraCirc 52 to 74 DuraCirc 32 to 43 8 Fit the bearing shaft...

Page 36: ...of the gearcase 3206 0073 12 Identify the drive 51 and auxiliary 52 shaft positions according to the gearcase cover 5 orientation or original pump specification 13 1 Lightly oil the bearing bores of t...

Page 37: ...d press new lip seals 36 until flush with front face 3 Lubricate with a small amount of lubricant and fit a new O ring 37 to the seal retainer 4 Apply a small amount of gearbox oil to the inner lip of...

Page 38: ...tors to allow measurement of the rotor wing face to face axial alignment 2 Using a depth micrometre ensure axial alignment is within a tolerance of 0 015mm 0 0006 in across each wing rotating the roto...

Page 39: ...gearcase 6 Refit the shaft following the instructions in step 13 7 Refit the seal retainer and tighten 8 Repeat steps 17 and 18 above to verify rotor abutment is now within tolerance 9 Return to step...

Page 40: ...r the table below If not loosen the TLA slightly and repeat Step 21 3 Timing adjustment is now required Model Dimension X mm 32 33 34 1 5 42 43 4 0 52 53 54 6 0 62 63 9 5 72 73 74 6 0 x 3206 0061 22 A...

Page 41: ...if required 5 Measure the rotor wing tip to tip gap is equal on both sides If not hold the top rotor or right rotor firmly and tap the other rotor with a soft mallet to adjust the timing 6 Recheck th...

Page 42: ...cut or damaged then secure with the gearbox cover screws 42 NOTE It is recommended to allow the sealant time to set before filling with oil Follow the recommendations of the sealant manufacture 3206...

Page 43: ...ing of the rotorcase will be required In this case please proceed to step 28 Note Your supplier can advise the correct clearances from the pump serial number Any incorrect setting of clearances is lik...

Page 44: ...e rotors 3 observing the correct position as marked during disassembly refit rotor nuts 4 and tighten 3206 0065 30 1 Using feeler gauges to check the back clearance rear rotor face to rotorcase and a...

Page 45: ...ound with the counter sunk holes visible and check the screws do not sit proud of the shim retainer 5 Repeat step 30 above to recheck the clearances 32 Once the clearances have been checked and are wi...

Page 46: ...rive shaft 51 by hand and check all clearances with a suitable gauge against recommended clearance figures as shown in seperate addendum for Pump Head Clearances 36 Fitting rotorcase cover 1 Lubricate...

Page 47: ...ons of the rotors and rotorcase e g Top Bottom or Left Right prior to removal to ensure the parts are refitted in the same positions 3206 0042 105 101 102 104 103 2 1 Remove rotorcase cover 1 and roto...

Page 48: ...atic assembly is fully seated by checking dimension shown below against the table If not remove the static assembly refit and check 3 Lubricate the squad ring 104 and fit to the static seal face 103 e...

Page 49: ...be facing away from the rotary seal face 7 Align the cut out on the rotary seal face 102 with the pins in the bore of the rotor 3 and press back gently until fully seated 8 Wipe clean the rotary seal...

Page 50: ...to removal of the parts are refitted in the same position Ensure the flush system has been de pressurized and is isolated before continuing 3206 0047 105 101 102 104 103 111 5 Single flushed mechanica...

Page 51: ...torcase 2 until flush with end of bore 2 Refit the rotorcase ensuring the rotor case screws 11 are torques to tightening the rotorscrews to the required torque setting as shown in Section 6 3 Follow i...

Page 52: ...same position Ensure the flush system has been de pressurised and is isolated before continuing 3206 0048 110 106 107 109 108 105 101 102 104 103 8 1 Follow instructions 1 to 4 as for the single seal...

Page 53: ...ck ensuring the static assembly is kept square to the bore until fully engaged 4 Lubricate the outboard static O ring 107 with appropriate grease and fit to the outboard static seal face 108 5 Align t...

Page 54: ...inner sleeve o ring 124 and outer sleeve o ring 125 from the sleeve Check sleeve for grooves and deep scratches and replace as necessary A small diameter tool can be passed through the holes in the f...

Page 55: ...e static assembly 121 Align the mark on the front face of the static assembly with the lugs in the bore of the rotorcase 2 and push back ensuring the static assembly is kept square to the bore until f...

Page 56: ...cover 1 as per the main assembly instructions in Section 5 4 8 Flushed seals only Refit the flush pipework and refill checking for any leaks and correct operation before restarting the pump 3206 0114...

Page 57: ...ration 15 minutes after pump shut down Disassembly NOTE It is recommended to mark the positions of the rotors and rotorcase e g Top Bottom or Left Right prior to removal to the parts are refitted in t...

Page 58: ...and tighten to the values given in the table below 4 Refit the rotorcase 2 rotors 3 rotor nuts 4 and rotorcase cover 1 as per the main assembly instructions in Section 5 4 5 Refit jacket connection p...

Page 59: ...uce pump speed x x x x Fluid vaporising in suction line Increase suction line diameter Increase suction head Simplify suction line configuration and reduce length Reduce pump speed x x x x x Air enter...

Page 60: ...and adjust mounting accordingly x x x x Insecure pump driver mount ings Fit look washers to slack fasteners and retighten x x x x x x x x Shaft bearing wear or faliure Refer to pump maker for advice a...

Page 61: ...Horizontal ports Vertical ports 32 32 70 33 72 73 160 74 163 33 33 72 34 74 81 178 82 180 34 36 79 37 81 88 194 89 196 42 60 132 63 138 151 332 154 339 43 63 138 66 145 157 346 160 352 52 110 242 113...

Page 62: ...10 10 7 10 10 7 13 20 15 13 20 15 Screw Torque Lock Assembly 62 Socket Size mm Torque Setting Nm Torque Setting lbft 5 17 13 5 17 13 6 41 30 6 41 30 6 41 30 Plug Drain 46 Key Size mm Torque Setting Nm...

Page 63: ...1 92 2 86 4 14 42 2 62 7 91 5 50 8 75 3 110 100 150 150 4 6 6 40 25 16 580 362 232 600 600 600 Please Note Maximum pump differential pressure may be limited based on the connection type used as below...

Page 64: ...ic Max Pump Speed Max Pump Pressure O ring Seal 300 7 102 Maximum Flush Pressures Mechanical Seal Single Flush 0 5 bar 7 psi Mechanical Seal Double Sic Carbon 1 bar above pump discharge upto 16 bar 23...

Page 65: ...6 2 Pumphead Clearance information For pump head clearances please see separate addendum sheet 200002348 1 EN GB 65 Technical data 6 EN...

Page 66: ...200002348 1 EN GB 66 6 Technical data EN...

Page 67: ...list 7 1 DuraCirc Pump Range 8 1 5 9 10 11 2 12 13 14 17 19 18 36 40 34 22 37 32 41 39 31 43 47 35 42 38 45 46 44 33 41 4 6 3 7 51 65 54 55 54 56 57 53 60 58 59 60 61 62 52 3206 0050 200002348 1 EN G...

Page 68: ...ner Shim 14 4 Screw Shim retainer 17 2 Heating jackets 18 2 O ring Heating jacket 19 8 Screw Heating jacket 22 2 Guard gland 31 1 Gearcase 32 1 Foot Vertical port 33 1 Foot Horizontal port 34 2 Retain...

Page 69: ...t Drive 52 1 Shaft Auxillary 53 1 Shim Gearbox 54 4 Bearing Front 55 2 Spacer Bearing 56 2 Washer tab lock 57 2 Nut Shaft 58 2 Bearing Rear 59 2 Circlip Shaft 60 4 Circlip Bearing DuraCirc 32 to 43 On...

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Alfa Laval DuraCirc Range, Instruction Manual

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