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Borger Classic FL 1036 Operating Manual Download Page 159

6.3.5 

Replacing the casing liners

1

Hexagon socket head cap screw

2

Sealing washer

3

Clamping part

4

O-ring

5

Casing liner

6

O-ring groove

Personnel:

n

Mechanics

Protective equipment:

n

Occupational safety clothing, chemical
resistant

n

Safety shoes

n

Safety gloves, chemical-resistant

n

Safety goggles

Special tool:

n

Tools, general

n

Torque wrench

— Read and follow the safety instructions detailed in 

Ä

 Chapter

2.12 “Safety instructions for maintenance and rectifying mal-
functions” on page 30

.

— Shut down the Börger machine and downstream and upstream

system components as described in 

Ä

 Chapter 5.3 “Down-

times” on page 93

.

— Secure the Börger machine against unauthorized or uncon-

trolled reactivation as described in 

Ä

 Chapter 2.7 “Securing the

machine against restart” on page 24

— To the extent necessary, amply secure the surrounding area

when performing maintenance. Cordon off the working area
with a red and white safety chain and a warning sign.

Maintenance and Repairs

BA-Classic FL_en-US, 03.05.2018

www.boerger.de / www.boerger.com

159

Summary of Contents for Classic FL 1036

Page 1: ...Börger Rotary Lobe Pump Classic Operating Manual FL Series www boerger de www boerger com ...

Page 2: ...r Tower Place Chanhassen MN 55317 USA Phone Fax E mail Internet 1 877 7263743 1 612 4357300 1 612 4357301 america boerger com www boerger com Asia Australia Oceania Singapore Boerger Pumps Asia Pte Ltd 16 Boon Lay Way 01 48 TradeHub21 Singapore 609965 Phone Fax E mail Internet 65 65629540 65 65629542 asia boerger com www boerger com China Boerger Pumps Shanghai Co Ltd Room 1009 No 939 JinQiao Road...

Page 3: ... 49 0 2862 9103 0 49 0 2862 9103 46 info boerger de www boerger de Spare parts orders and customer service in Germany Phone Fax E mail 49 0 2862 9103 31 49 0 2862 9103 49 service boerger de Spare parts orders and customer service in other countries See separate contact data for your regional sales partner Document data Document Issue date Language BA Classic FL_en US 03 05 2018 English translation...

Page 4: ...upling guard 26 2 8 3 Intermediate chamber 26 2 8 4 Optional monitoring devices 26 2 9 Markings and signs 27 2 10 Markings and signs to be attached by the operator 29 2 11 Safety instructions for operating personnel 29 2 12 Safety instructions for maintenance and rectifying malfunctions 30 2 13 Information on special dangers 36 2 13 1 Oil grease and other chemical substances 36 2 13 2 Noise 36 3 P...

Page 5: ... and outlet 68 4 4 4 Aligning the unit 71 4 4 5 Electrical hydraulic and PTO shaft connection 73 4 5 Checks before commissioning 79 4 5 1 Checking smooth running following storage and long downtimes 80 4 5 2 Checking readiness for operation 81 4 5 3 Checking the flow direction 83 5 Operation 86 5 1 Commissioning 89 5 1 1 Test run with medium 90 5 1 2 Complete commissioning 91 5 2 Continuous operat...

Page 6: ...65 6 3 9 Queries 166 7 Disposal 167 7 1 Environmental protection 167 7 2 Oil oily waste and grease 167 7 3 Plastics 167 7 4 Metals 168 7 5 Electrical and electronic waste 168 7 6 Final decommissioning 168 8 Accessories 169 8 1 Frequency converter 169 8 2 Monitoring equipment 169 8 2 1 Dry run protection 169 8 2 2 Pressure monitoring devices as overpressure protection 170 8 2 3 Pressure relief valv...

Page 7: ... Lubricant list 187 9 8 1 Börger gear units 188 9 8 2 Buffer fluid 189 9 8 3 Oil properties 190 9 8 4 Oil types 192 9 8 5 Oil filling quantity of the Börger units 195 9 8 6 Lubricant orders 197 9 8 7 Customer approval for special lubricants example 198 9 9 Additional documentation 199 9 10 Supplier documentation 199 10 Index 200 Table of Contents BA Classic FL_en US 03 05 2018 www boerger de www b...

Page 8: ...eshooting Maintenance machine care maintenance and repairs Transportation 1 2 Notes on copyrights and property rights This operating manual must be treated as confidential It may only be made accessible to authorized persons The manual may only be passed on to third parties following written approval from Börger GmbH All documents are protected according to the copyright laws The distribution and ...

Page 9: ...f operation and at the instal lation site all recognized special regulations for safe and proper operation must be observed The operator is not permitted to make or arrange for any changes modifications or alterations to the Börger machine without approval from Börger GmbH Any spare parts used must comply with the technical requirements specified by Börger GmbH This is always guaranteed when orig ...

Page 10: ...ed Only then can your personnel work safely and be fully aware of associated risks Adherence to instructions must be checked on a regular basis As the operator you should therefore have each instructed staff member confirm their training participation in writing Sample training topics and a sample form for confirming participa tion in the training instruction can be found on the following pages Bö...

Page 11: ... machine Explanation of the operating manual for operating personnel Specific experiences in using the Börger machine Troubleshooting dealing with malfunctions ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ 3 Repair and maintenance regulat...

Page 12: ... Training topic Date Trainer Trainer signature No Surname first name Signature 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 General information BA Classic FL_en US 03 05 2018 www boerger de www boerger com 12 ...

Page 13: ...properly 2 2 Notes on signs and symbols The following terms signs and symbols are used in this operating manual and indicate particularly important information DANGER Warns of an immediate hazardous situation with unavoidable serious injuries or death as a result if the instructions shown are not strictly adhered to WARNING Warns of a hazardous situation with the possible risk of subse quent serio...

Page 14: ... indicate lists Ä Arrow symbols indicate references to further chapters WARNING Danger due to illegible signage Over time stickers and signs can get soiled or become illegible due to other reasons so that dangers are not recognized and necessary operating instructions cannot be observed This poses a risk of injury Do not remove any safety notes warnings and operating instructions Keep them complet...

Page 15: ... images used in this operating manual which are only used to illustrate a function or a particular work step show a different type of device however the functional principle or work step is the same Safety BA Classic FL_en US 03 05 2018 www boerger de www boerger com 15 ...

Page 16: ... specified in the order confirmation and enclosed data sheet Observe the technical specifications in the data sheet Therefore proper use is restricted to the specified flow medium temperatures speeds and output only Proper use includes compliance with the instructions on safety operation and control repairs and maintenance specified in this operating manual Any other use or use over and above thes...

Page 17: ...ed Damage to the insulation of the individual components can be fatal Have all work on the electrical equipment performed by skilled electricians In the event of damage to the insulation cut off the power supply immediately and initiate repairs Before working on live components of electrical systems and equipment de energize these components and secure them in this state for the duration of the wo...

Page 18: ...f the safety equipment on page 25 and fully functional before putting the machine into operation The Börger machine must only be switched on when the inlet and outlet connections have been established and the maintenance openings have been securely installed CAUTION Risk of burns Particularly when used outside at correspondingly high ambient temperatures and high medium temperatures individual par...

Page 19: ...ons Therefore wear your personal protective equipment PPE as described in Ä Chapter 2 6 Personal protective equipment on page 23 when opening the cover and take all necessary precautions CAUTION Health hazard due to residues of dangerous medium inside and on the Börger machine There is an increased health hazard from contact with the medium and contaminated components Generally the following appli...

Page 20: ...on are not approved The operating personnel must have been informed or instructed on the applicable legal and accident prevention regulations as well as the safety equipment on and around the Börger machine The operating personnel must have fully understood the instructions and adherence to the instructions must be guaranteed Only then can all personnel work safely and in full awareness of the ass...

Page 21: ...d in these instructions on the system and its com ponents The knowledge acquired during further training enables operating persons to identify and evaluate hazards associated with the system and its components These include Knowledge about health and safety at work Knowledge about the basics of first aid Technical knowledge Knowledge about assembly maintenance and repair Knowledge about machine op...

Page 22: ...ns with the system and its components The knowledge acquired during further training enables warehouse workers to identify and evaluate hazards associated with the system and its components during transport and storage These include Knowledge about health and safety at work Knowledge about the basics of first aid Receiving goods and checking them for completeness and integrity Selecting storage lo...

Page 23: ...l dusts Occupational safety clothing chemical resistant The chemical resistant occupational safety clothing is used to pro tect the skin from contact with chemicals which are a health hazard Safety gloves chemical resistant Chemical resistant safety gloves are used to protect the hands from corrosive chemicals Safety goggles Safety goggles closed on all sides are used to protect the eyes from flyi...

Page 24: ...ding to Ä Chapter 2 7 Securing the machine against restart on page 24 1 Shut off the media supply by closing the respective shut off valves 2 Shut off the energy supply 3 Inform the person responsible that work is being carried out in the danger area 4 Attach a sign to the control cabinet to indicate that work is being carried out in the danger area and that switching on is prohibited The sign mus...

Page 25: ...ology and recognized safety regulations 2 8 1 EMERGENCY STOP When pressing the EMERGENCY STOP button the machine is shut down by the energy supply being switched off or the machine being mechanically disconnected from the drives Once the EMERGENCY STOP switch has been activated it must be turned in order to reset it and restart the machine WARNING Risk of fatal injury due to an unauthorized and un...

Page 26: ...t from the timing gear It is used for monitoring the integrity of the mechanical seals on rotary lobe pumps with single acting mechan ical seals Overflowing caused by penetrating pumped medium indicates that the mechanical seals must be replaced immediately in order to prevent the pumped medium from entering the gear unit The vent hole in the intermediate chamber must not be sealed or plugged When...

Page 27: ...e stickers and signs can get soiled or become illegible due to other reasons so that dangers are not recognized and necessary operating instructions cannot be observed This poses a risk of injury Do not remove any safety notes warnings and operating instructions Keep them completely legible Replace damaged signs or stickers immediately Safety BA Classic FL_en US 03 05 2018 www boerger de www boerg...

Page 28: ...ng Do not touch rotating parts risk of serious permanent injury Location In a clearly visible position on the rotary lobe pump Meaning Close the safety opening of the intermediate chamber with a safety plug do not leave it open do not close it with a screw do not close it tightly with a screw plug Location In a clearly visible position on the machine Meaning Please read the operating manual carefu...

Page 29: ...rstood this operating manual beforehand specifically Ä Chapter 2 Safety on page 13 Consulting the manual during work is already too late This applies especially to personnel that only work occasionally on the Börger machine The operating manual must always be kept accessible next to the Börger machine No liability will be assumed for any damage and accidents caused by non compliance with the opera...

Page 30: ...peri enced staff member 2 12 Safety instructions for maintenance and rectifying malfunctions Adhere to the prescribed intervals for regular maintenance and inspections or those specified in the operating manual Aside from the special tools specified in the spare parts list suit able customary workshop equipment is essential for carrying out maintenance work Modifications repairs maintenance and tr...

Page 31: ...oting maintenance and repair work can lead to severe injury and significant damage to property Ensure sufficient installation space before commencing work Keep the installation site clean and tidy Loosely stacked or scattered components and tools cause accidents Ensure correct installation where components have been removed reinstall all fastening elements and observe the tightening torques of scr...

Page 32: ...Risk of fatal injury if safety devices are not fully functional Non functional or overridden safety features may cause severe injuries including death Check whether all safety features are functional and correctly installed before starting work with the machine Never override or bypass safety features Ensure that all safety features are accessible at all times WARNING Risk of injury when using uns...

Page 33: ...unctions and damage Do not use water jets Do not use aggressive cleaning agents solvents or sand paper as these can damage the metallic and plastic surfaces casing coating and seals Do not use metal objects such as scrapers and screwdrivers for cleaning coated machine parts Never clean sensitive components with hard scrubbing and strong mechanical pressure Do not use a vacuum cleaner or a hand bru...

Page 34: ...re to the prescribed intervals for regular maintenance and inspections or those specified herein and in the operating manuals of the components 3 Carry out modifications repairs maintenance and trouble shooting on the control unit only when the electrical system is switched off Accidental restarting of the unit must be pre vented completely 4 To the extent necessary amply secure the surrounding ar...

Page 35: ...able agents according to the manufacturers operating manuals only Do not use aggressive cleaning agents to clean the surface Use lint free cleaning cloths 8 Dispose of any replacement parts in a safe and environmen tally friendly manner Safety BA Classic FL_en US 03 05 2018 www boerger de www boerger com 35 ...

Page 36: ...ions and safety data sheets issued by the respective manufacturer relating to storage handling correct use and disposal Comply with the legal obligations regarding waste avoidance and the proper recycling disposal of waste during all work When handling oil grease and other chemical substances pay attention and adhere to the applicable regulations and safety data sheets issued by the respective man...

Page 37: ... sight glass 4 2 Breather oil filler for gear unit 4 3 Oil drain for gear unit 4 4 Two shafts with parallel axes drive shaft can optionally be at position 0 or 1 5 Shaft seal on pump chamber 6 Intermediate chamber quench 6 1 Intermediate chamber fill hole 6 2 Drain from intermediate chamber 6 3 Breather Components Construction Product Description BA Classic FL_en US 03 05 2018 www boerger de www b...

Page 38: ...plementary operating manual in the Appendix contains a description of other cover types if these types have been supplied 3 1 2 Casing The EL rotary lobe pump is available in three casing depths The performance data of your rotary lobe pump depends on this depth among other things Depths FL 518 FL 776 FL 1036 Also see Ä Chapter 3 3 Technical data on page 49 The block type one piece casing is equip...

Page 39: ...inless steel Pos 9 7 in the spare parts list Type E Tri lobe linear Removable lobe tips Pos 9 2 in the spare parts list Type F Tri lobe linear Stainless steel rotor body Removable lobe tips Pos 9 2 in the spare parts list Type G Tri lobe screw profile Removable lobe tips Pos 9 1 in the spare parts list Type H Tri lobe screw profile Stainless steel rotor body Removable lobe tips Pos 9 1 in the spar...

Page 40: ... of rotation can be changed by switching the PTO shaft The timing gear is equipped with a breather system to compensate for increased pressure due to rising temperatures The breather system must always be installed on the highest point of the rotary lobe pump compare the illustrations of the versions for the dif ferent mounting positions in Ä Chapter 3 1 7 Designs mounting positions on page 42 3 1...

Page 41: ...amber and gear chamber are separated by an inter mediate chamber filled with quench fluid as standard The heat absorbing quench fluid prevents the mechanical seals from running dry and captures any medium that enters the inter mediate chamber due to leaks in a mechanical seal This quench function also prevents the gear unit from being damaged by intru sion of the medium The contact area between th...

Page 42: ...pump type and the mounting position the posi tion of the oil sight glass breathers fill holes as well as the drain holes for the gear unit and for the intermediate chamber can vary Observe the assembly drawing Ä Chapter 9 3 Assembly drawing on page 175 and the spare parts list Ä Chapter 9 4 Spare parts list on page 177 of your rotary lobe pump NOTE Special version On immersion models special versi...

Page 43: ...n M3 Upside down feet upwards horizontal shafts Fig 5 Example Classic FL series Mounting position M5 Turned 90 to the left feet to the right horizontal shafts Fig 6 Classic FL series Mounting position M6 Turned 90 to the right feet to the left horizontal shafts Product Description BA Classic FL_en US 03 05 2018 www boerger de www boerger com 43 ...

Page 44: ...ned for the different applications and mounting conditions The inlet and outlet can be equipped with the same or different pipe connectors Pipe connectors are available with a variety of connections for example DIN EN flange ANSI ASME flange Quarter turn coupling Quick release coupling e g Perrot female adapter optional male Dairy screw connections and others The pipe connectors can be equipped wi...

Page 45: ...ion towards the front back top bottom or side Angled version connection towards the front back or side Angled version for narrow installations connection towards the front back top or bottom Continuous fully pivotable suction and pressure connec tion with quick release coupling e g Perrot system Product Description BA Classic FL_en US 03 05 2018 www boerger de www boerger com 45 ...

Page 46: ...orsionally flexible coupling 3 Coupling guard 8 Drive with gear reducer in this example 10 Base frame 11 Pipe connector short straight pipe connector with flange in this example 12 Motor plate Overhead mounted drive assembly piggyback 1 Börger Rotary lobe pump 4 V belt pulley chain drive 5 V belt up to five belts depending on the drive or chain drive 6 V belt chain guard 8 Drive with gear reducer ...

Page 47: ...ne according to its application You will find explanations referring to the special equipment and any delivered accessories in the appendix NOTICE Risk of material damage due to non compliance with the operating manuals for accessories Non compliance with supplementary operating manuals for spe cial equipment or accessories can lead to damage to the Börger machine If your Börger machine is equippe...

Page 48: ...direction of rotation of the drive This vacuum draws the liquid into the pump chamber The dynamic transfer from the suction chamber to the pressure chamber 2 allows low pulsation pumping and nearly pulsation free pumping when screw rotors are used The pumped medium is forced into the pressure lines on the pressure side 3 through the rotating intermeshing rotors The symmetrical construction of the ...

Page 49: ...tact Börger customer service if you require a copy of this drawing 3 3 1 Dimensions Dimensions without attachment parts Dimensions approx mm approx inch FL 518 FL 776 FL 1036 FL 518 FL 776 FL 1036 D 311 373 5 395 12 24 14 70 15 55 E 687 749 5 791 27 05 29 51 31 14 F 551 551 551 21 69 21 69 21 69 G 340 340 340 13 39 13 39 13 39 H 290 290 290 11 42 11 42 11 42 J 325 325 325 12 80 12 80 12 80 ØK 48 4...

Page 50: ...ensional drawing created for the order We deliver short straight pipe con nectors as standard with flanges selectable according to DIN EN 1092 1 type 11 ANSI ASME B 16 5 RF Class 150 Dimensions A and B in mm approx FL 518 FL 776 FL 1036 Stand ard DIN DIN EN ANSI ASME DIN DIN EN ANSI ASME DIN DIN EN ANSI ASME Dimen sion A B A B A B A B A B A B Nom inal diam eter DN 100 4 206 752 230 800 206 752 Pip...

Page 51: ...A B A B A B A B A B A B Nom inal diam eter DN 100 4 8 11 29 61 9 06 31 50 8 11 29 61 DN 125 5 6 54 26 46 7 87 29 13 7 91 29 21 9 25 31 89 DN 150 6 6 93 27 24 8 27 29 92 6 93 27 24 8 27 29 92 8 90 31 18 10 24 33 86 DN 200 8 9 88 33 15 11 46 36 30 5 94 25 28 7 52 28 43 7 91 29 21 9 49 32 36 DN 250 10 8 70 30 79 9 88 33 15 11 22 35 83 7 91 29 21 9 25 31 89 When using two 2 mm 0 08 gaskets 4 mm 0 16 m...

Page 52: ...nit etc can be found in the corresponding manufacturer s documentation The weight of the complete unit is specified in the data sheet 3 3 2 Performance data and maximum loads The specification of the pump output for which the rotary lobe pump was actually configured can be found in the data sheet The geometric displacement volume of the pump series is as fol lows Base frame Complete unit Rotary lo...

Page 53: ...308 617 30 240 132 1057 150 400 50 600 0 7 bar 21 HG vac 8 bar1 116 psi 1 FL1036 90 180 396 793 40 330 176 1454 150 400 50 600 0 7 bar 21 HG vac 6 bar1 87 psi 1 1 Pumps that are switched in series can have a higher maximum permitted working pressure at the second pump see data sheet The limit mentioned here applies to the difference in pressure between the inlet and outlet which must also be obser...

Page 54: ...800 2680 For comparison Specification acc to EN 14847 200 930 1320 500 735 250 1140 1620 625 920 The values Fx Fy and Fz as well as Mx My and Mz may never be used simultaneously as maximum values The specified values are calculated and may deviate in practice due to casting tolerances and structural changes It is therefore recommended not to exceed the limits specified in terms of EN ISO 14847 for...

Page 55: ...belts Do not place hoists such as ropes and belts near sharp cor ners and edges and do not tie them together or twist them Put the load down when leaving the operating site WARNING Risk of injury by falling or tilting packages Packages can have their center of gravity elsewhere than in the middle If not properly aligned the package can tilt and fall Falling or tilting packages can cause severe inj...

Page 56: ...ations in the hoist instructions especially for the inclination angle allowed 2 Transport the Börger machine using a suitable hoist 3 If a special base frame with additional lifting lugs or forklift pockets was delivered use them accordingly Without attachment parts Börger machines of type FL can be lifted using the ring bolt Standard Börger machines of type FL with electric drives can be transpor...

Page 57: ...n page 30 The Börger machine is delivered in a pre assembled packed state Optional accessories may be included in separate pack aging 1 Observe the applicable delivery conditions for the order 2 Check that the delivery is complete when you receive it 3 Inspect the delivery immediately for any signs of transport damage 4 Ensure that the unit is not put into operation in the event of incorrect or in...

Page 58: ...ording to Ä Chapter 4 5 1 Checking smooth running following storage and long downtimes on page 80 This way the gears bearings and shaft seals are moved and coated again with lubricant If the Börger machine is not used immediately then appropriate storage conditions are as important as the correct installation and maintenance for subsequent trouble free operation Transportation Storage and Installa...

Page 59: ...xposure to direct heat sources sunlight heating 1 Repair any damage to the external coating galvanized com ponents and corrosion protection on bare metal parts caused by external influences 2 Protect the Börger machine from cold particularly from frost as well as from moisture contamination and mechanical influ ences Close the inlet and outlet connections in particular flange coupling etc plus any...

Page 60: ...ver in accordance with Ä Chapter 6 3 2 Opening and closing the quick release cover on page 125 1 Replace the lubricants before commissioning as described in Ä Chapter 6 2 2 Lubricant fill level and changing the lubri cants on page 116 2 Check all O rings that come into contact with the medium and the mechanical seal and replace them if necessary as described in Ä Chapter 6 3 4 Replacing the mechan...

Page 61: ...ns for maintenance and rectifying mal functions on page 30 To the extent necessary amply secure the surrounding area when performing maintenance Cordon off the working area with a red and white safety chain and a warning sign 1 Clean the Börger machine thoroughly in accordance with Ä Chapter 6 1 Machine care on page 106 2 Apply suitable corrosion protection to the machine 3 Follow the storage inst...

Page 62: ...area 4 4 1 Preparation for installation NOTE Pipe layout Check that the original pipe layout is still correct before installing the pump A change in pipe diameter length etc can completely change the suction and pressure conditions in the system Börger rotary lobe pumps are configured for different mounting positions Refer to the diagram in Ä Chapter 3 1 7 Designs mounting positions on page 42 for...

Page 63: ... operating manuals for accessories Non compliance with supplementary operating manuals for special equipment or accessories can lead to damage to the Börger machine If your Börger machine is equipped with special equip ment then you must first read the corresponding supple mentary operating manual for the equipment or accesso ries before carrying out any installation commissioning maintenance or r...

Page 64: ...a when performing installation Cordon off the working area with a red and white safety chain and a warning sign 1 Base frame Attach the Börger machine to a solid rigid surface 2 Drive Connect the Börger machine which is installed on a Börger base frame or a suitable rigid surface to a suitable drive Observe the appropriate speed and sufficient torque and take all necessary parameters into account ...

Page 65: ...ral sector 5 Gradually tighten the flange screws used to install the pipe connectors on the inlet and outlet crosswise so that the leak tightness of the connection is guaranteed Make sure that the seals and the spring washers are not damaged and not to squeeze out the rubber gaskets NBR EPDM FKM Torque O ring seals and PTFE based gaskets M12 steel screws 80 Nm 59 ft lbs M12 stainless steel screws ...

Page 66: ... s operating manual Standard units are installed ready for operation on a rigid base frame together with elastic shaft connections a coupling guard and pipe connectors The recommended service space A x A is 1 0 x 1 0 m 3 28 ft x 3 28 ft A space of at least 0 8 m x 0 8 m 2 62 ft x 2 62 ft is necessary to access the unit easily for maintenance and repair work Risk of frost Sufficient air circulation...

Page 67: ...d follow the safety instructions detailed in Ä Chapter 2 12 Safety instructions for maintenance and rectifying mal functions on page 30 To the extent necessary amply secure the surrounding area when performing installation Cordon off the working area with a red and white safety chain and a warning sign 1 Position the base frame without subjecting it to stress 2 Compensate for any unevenness in the...

Page 68: ... pipe system Börger machines are robust and are constructed for use with high loads However they must not be used as an anchor point for the pipe under any circumstances Even at low vibrations the stress generated on the pipe during operation can lead to cracks on weaker components weld seams Pipes and any additional components such as valves check valves etc must not subject the machine and flang...

Page 69: ...o equip the pipe system with vents at high points Ensure that no pockets of air can build up upstream or downstream of the pump Suitable seals are required for installing the inlet and outlet pipe connectors to the pipes hoses i e gaskets are required on flange connections These must be resistant against the medium The type design nominal diameter and nominal pressure of the connection flanges or ...

Page 70: ...er connections before installation and ensure that they are not damaged 2 On flange connections ensure that the flanges are positioned exactly face to face even without being fixed by screws They must not be inclined nor pressed together nor spring backwards due to tensile forces 3 Prevent any stress on the pipes connected to the Börger machine by taking suitable measures 4 Use seals that are suit...

Page 71: ...serve the instructions from the coupling manufac turer in the appendix To the extent necessary amply secure the surrounding area when performing installation Cordon off the working area with a red and white safety chain and a warning sign 1 Loosen the fastening screws of the coupling guard and pull the coupling guard out of the groove of the fastening ring if available depending on version 2 Bend ...

Page 72: ...tions detailed in Ä Chapter 2 12 Safety instructions for maintenance and rectifying mal functions on page 30 Read and observe the instructions from the V belt or chain manufacturer in the appendix To the extent necessary amply secure the surrounding area when performing installation Cordon off the working area with a red and white safety chain and a warning sign 1 Open the retaining clamps 2 on th...

Page 73: ...y stop device if the emergency stop device would not reduce the stopping time and if it would not enable the special measures required to deal with the risk to be taken The normal shutdown equipment must then be labeled accordingly The installation of the Börger machine must have been concluded completely before the electric or hydraulic connections are made or the PTO shaft is connected EMERGENCY...

Page 74: ... the duration of the work Adhere to the fol lowing safety rules in this regard Disconnect Secure against restart Verify that components have been de energized Ground and short circuit Cover or shield any adjacent live components Never bypass or disable any fuses Comply with the correct amperage specification when replacing fuses Keep moisture away from all live components This may lead to short ci...

Page 75: ...y secure the surrounding area when performing installation Cordon off the working area with a red and white safety chain and a warning sign 1 Connect all electrical monitoring devices according to the operating manuals from the manufacturers 2 Connect the drive on versions with an electric drive according to the operating manual from the manufacturer 3 Ground the Börger machine properly see operat...

Page 76: ... Never hold body parts or any objects into the jet of liquid Keep personnel away from the hazardous area Activate the EMERGENCY STOP immediately If required take further measures to reduce the pressure and stop the jet of liquid Have defective components repaired immediately Collect any escaping fluid properly and dispose of it Instructions and safety regulations Pay particular attention to all in...

Page 77: ...th a red and white safety chain and a warning sign Connect the hydraulic connections on Börger machines with a hydraulic drive according to the operating manual from the drive manufacturer WARNING Danger of crushing injuries when connecting the PTO shaft Moving parts can cause severe injury PTO shaft connections may only be installed by qualified technicians Instructions and safety regulations Pay...

Page 78: ...hen performing installation Cordon off the working area with a red and white safety chain and a warning sign 1 On versions with a PTO shaft drive ensure that the drive side of the PTO shaft is properly connected to the drive 2 Connect the suitable PTO shaft which has to be mounted properly to the drive with the corresponding shaft end of the Börger machine according to the operating manual from th...

Page 79: ...m work on the Börger machine only when stationary Observe the delay time Prior to opening protective covers make sure that all components have stopped moving Shut down the Börger machine and upstream and down stream system components as described in Ä Chapter 5 3 Downtimes on page 93 before carrying out any work on the Börger machine or accessories The operating person is obligated to check that a...

Page 80: ... and the rotating parts run smoothly before commissioning the Börger machine again Open the quick release cover see Ä Chapter 6 3 2 Opening and closing the quick release cover on page 125 and attach a hexagon socket wrench or ratchet to one of the hexagon socket head cap screws that fasten the rotating parts to the shafts Use the tool to rotate the shaft clockwise The shafts and the rotating parts...

Page 81: ...low the safety instructions detailed in Ä Chapter 2 12 Safety instructions for maintenance and rectifying mal functions on page 30 Ensure that the Börger machine is integrated into an emer gency stop system or if such a system is not mandatory that the shutdown device is adequately labeled 1 If your Börger machine was delivered with special accesso ries then ensure that these accessories are insta...

Page 82: ...quench fluid see enclosed data sheet is suitable or whether an alternative fluid must be used in order to observe environmental protection regula tions or for biological or other reasons This must be compat ible with the medium and must not adversely affect the O rings of the mechanical seals Consult Börger GmbH regarding this if necessary 7 Check the fill level in the intermediate chamber On stan...

Page 83: ... to the pump components A rotary lobe pump with rubber coated rotors should not run dry i e without pumped medium for longer than 15 sec onds at a normal speed under any circumstances The rotary lobe pump must not be put into operation during the following function test Ensure that all valves and shut off devices are closed The flow direction on Börger rotary lobe pumps can be reversed and is defi...

Page 84: ...ow direction from left to right when the upper shaft turns clockwise Þ Required direction of rotation of the shaft the fan wheel when looking at the drive counter clockwise 1 If the lower shaft is the drive shaft the motor of a version with a two stage helical gear unit must turn in the other direction when looking at the drive than shown here Transportation Storage and Installation BA Classic FL_...

Page 85: ... in the opposite direction for example when looking at the drive This is different from two stage gear units which are used as an example here 2 Check the direction of rotation of the drive shaft for example by briefly switching on the motor and observing the fan wheel of the motor 3 If the direction of rotation and therefore the flow direction are incorrect change the direction of rotation of the...

Page 86: ...and notes pro vided in this manual Ensure that all operating steps are performed as per the infor mation and notes provided in this manual Ensure the following before starting work Ensure that all covers and safety features are installed and function correctly Ensure that nobody is in the hazardous area Never bridge or disable safety features during operation Improper operation Operation BA Classi...

Page 87: ...issible differential pressure between the inlet and outlet of the Börger machine is not exceeded Make sure that the pressure on the outlet does not exceed the permissible pressure of the pipe system and the Börger machine and not overload the drive and its elastic connec tions The temperature values according to the data sheet may not exceed or fall below the limits Double check this NOTICE Risk o...

Page 88: ...f environmentally hazardous substances especially incorrect disposal can cause significant damage to the environment Especially water polluting materials such as grease and lubri cating oil must not pollute the soil or enter the sewage system during installation repair and maintenance work These materials must be collected stored transported and disposed of in suitable containers When handling oil...

Page 89: ...t time 5 1 Commissioning NOTICE Risk of damage to the mechanical seal due to a lack of quench fluid Risk of damage to the mechanical seal due to a lack of quench fluid The heat absorbing quench fluid prevents the mechanical seal from running dry and captures any medium that enters the intermediate chamber due to leaks in the mechanical seal This quench function also prevents the gear unit from bei...

Page 90: ...alves open to ensure the unrestricted transportation of pumped medium and any air remaining in the pipe 5 1 1 Test run with medium Personnel n Mechanics Protective equip ment n Occupational safety clothing chemical resistant n Safety shoes n Safety gloves chemical resistant n Safety goggles This test run may only be made when all safety instructions have been read and adhered to according to Ä Cha...

Page 91: ... for leaks 6 Check that the function display of all additional devices is working properly 7 Check that the Börger machine runs quietly and vibration free If the Börger machine or drive emits uneven rattling sounds then the cause must be determined 8 Check the power consumption of the drive Compare the values with those in the drive operating manual 9 Check the development of noises and temperatur...

Page 92: ...ous opera tion 1 Make sure that the unit does not become imbalanced due to inadequate cleaning adhesive residues of the pumped medium threads wrapped around the rotors or foreign bodies 2 On Börger rotary lobe pumps that operate with a frequency converter make sure that the operating speed is sufficiently below the maximum permissible speed for speed limit based on machine configuration see enclos...

Page 93: ...itch off the Börger machine or the pumps or the gravity feed depending on the system 2 Close the valves on the suction and pressure line if required by the system 3 The flow medium can be left in the Börger machine during normal downtimes provided the flow medium type does not prevent this e g medium hardens when cooling down Clean the Börger machine in these cases and before long downtime periods...

Page 94: ...ing the EMER GENCY STOP switch immediately NOTE EMERGENCY STOP The EMERGENCY STOP button as an EMERGENCY STOP enables the immediate shut down of the Börger machine 2 If a risk to your own life can be excluded evacuate other per sons from the danger zone 3 If necessary initiate first aid measures 4 Alert emergency personnel 5 Inform person responsible on site 6 Switch off the Börger machine and sec...

Page 95: ... following before putting the machine back into operation Ensure that all troubleshooting maintenance and repair work is performed and completed as per the information and notes provided in this manual Ensure that nobody enters the hazardous area Ensure that all covers and safety features are installed and function correctly WARNING Risk of injury when using unsuitable spare parts The use of unsui...

Page 96: ...il the cause has been rectified NOTE Observe the note regarding the sequence of the measures at the end of this chapter Fault description Cause Remedy Personnel The pump does not start or runs with difficulty after a downtime Drive not switched on not installed correctly or defective Establish the correct drive func tion by connecting it to the power supply installing it cor rectly etc Qualified e...

Page 97: ...e of the inlet line and clean the pump chamber before longer downtimes Mechanics Polymer rotors have expanded and press too strongly against the casing wall Determine the chemical compo sition and temperature of the pumped medium and use rotors made from suitable materials test plates for testing the expansion are available from Börger GmbH Mechanics Drive output too low Install a more powerful dr...

Page 98: ...pen with cross linked pipes Only open the shut off device of the suction line which is cur rently in pump operation Mechanics Viscosity of pumped medium too high Reduce the viscosity when pos sible Change the pump position or install an auger upstream Mechanics Build up of air pockets pump could not dis charge air on pressure side Provide venting Mechanics Rotors damaged due to dry run Replace the...

Page 99: ...eplace the rotors Mechanics Wear on casing liners or pump casing Replace worn parts Mechanics The pump emits rat tling noises Speed too high pump chambers only partially filled Reduce the speed Mechanics Operation BA Classic FL_en US 03 05 2018 www boerger de www boerger com 99 ...

Page 100: ...iently taking the weight of the pumped medium into account Mechanics Rotors incorrectly installed e g fastening screw of the rotors not tightened with the speci fied torque Install the rotors properly Mechanics Rotors or other compo nents broken by hard foreign bodies Replace damaged parts Install a macerator Multi crusher Multichopper and a stone trap upstream if neces sary Only use the rotary lo...

Page 101: ... Reduce the counter pressure Install pressure monitoring equipment Mechanics Speed too low Increase the speed Mechanics Viscosity of pumped medium too high Reduce the viscosity when pos sible Change the pump position or install an auger upstream Mechanics Rotors damaged due to dry run Replace the rotors Replace mechanical seal strongly recommended if rotors were damaged due to dry run Determine th...

Page 102: ...ultiSeal cartridges Mechanics Complete loss of quench fluid Unsuitable quickly evaporating quench fluid Use suitable quench fluid Adhere to temperature limits Mechanics Maintenance intervals exceeded Adhere to maintenance inter vals Fill intermediate chamber Exclude consequential damage to the seals by performing reg ular fill level checks and by checking the quality of the gear oil Mechanics Plea...

Page 103: ...ew rotors while the pump output remains too low then we also recommend replacing the pump casing Before replacing wear parts take advantage of the possibility of increasing the speed of the pump drive and thus the pump output On electric motors this can be an increase in frequency on your frequency converter this can also be above the mains frequency For example the speed can be varied on some dri...

Page 104: ...ened previously for firm seat 2 Check whether all safety devices and covers that have been removed previously are reinstalled properly 3 Ensure that all tools materials and other equipment used has been removed from the work area 4 Clean the work area and remove any spilled substances e g liquids processing material or similar 5 Reset the emergency stop devices if required 6 Confirm malfunctions a...

Page 105: ... spare parts may be used during the warranty period failing which the warranty is void WARNING Risk of injury due to inadequate troubleshooting mainte nance and repair work Inadequate troubleshooting maintenance and repair work can lead to severe injury and significant damage to property Ensure sufficient installation space before commencing work Keep the installation site clean and tidy Loosely s...

Page 106: ...s or ordering spare parts Ä Chapter 9 2 Wear parts on page 172 to Ä Chapter 9 4 Spare parts list on page 177 3 Read and strictly comply with the applicable regulations manufacturer s safety data sheets and operator s instructions in respect of the storage handling use and disposal of oils grease and other chemical substances 4 Dispose of operating materials and replaced parts in a safe and environ...

Page 107: ... not use metal objects such as scrapers and screwdrivers for cleaning coated machine parts Never clean sensitive components with hard scrubbing and strong mechanical pressure Do not use a vacuum cleaner or a hand brush with plastic bristles etc to clean electronic components because the pro duction of static electricity can damage the electronic compo nents Maintenance and Repairs BA Classic FL_en...

Page 108: ...s for maintenance and rectifying mal functions on page 30 Shut down the Börger machine and downstream and upstream system components as described in Ä Chapter 5 3 Down times on page 93 1 Keep all markings on the Börger machine in a legible state at all times 2 Only clean the outside of the Börger machine by wiping or brushing it down Use lint free cleaning cloths 3 When required use a standard aqu...

Page 109: ...ith the medium skin eye contact swal lowing inhaling Remove spillage from your skin without delay Do not store or consume beverages food or tobacco in the working area WARNING Severe injury due to residual pressure Despite having depressurized the Börger machine it may be under residual pressure in the event of congestion or lump forma tion in the medium Take extra care when removing the flange co...

Page 110: ...uncon trolled reactivation as described in Ä Chapter 2 7 Securing the machine against restart on page 24 To the extent necessary amply secure the surrounding area when performing maintenance Cordon off the working area with a red and white safety chain and a warning sign 1 Close all valves and shut off devices so that no medium can enter the working chamber of the Börger machine 2 Release the pres...

Page 111: ...mmediately absorb escaping media using suitable agents and dispose of it in accordance with the applicable local regu lations Therefore wear your personal protective equipment PPE as described in Ä Chapter 2 6 Personal protective equipment on page 23 when opening the cover and take all necessary precautions WARNING Severe injury due to residual pressure Despite having depressurized the Börger mach...

Page 112: ...to storage handling correct use and disposal Comply with the legal obligations regarding waste avoidance and the proper recycling disposal of waste during all work Personnel n Operating person Protective equipment n Occupational safety clothing chemical resistant n Safety shoes n Safety gloves chemical resistant n Safety goggles Special tool n Tools general Read and follow the safety instructions ...

Page 113: ...f the Börger machine 2 Thoroughly clean the rotating parts and the working chamber of the machine from deposits and contamination 3 Thoroughly clean all parts before reinstalling removed parts 4 Check all removed parts for wear and only reuse them if they are undamaged 5 Only replace worn components seals screws nuts etc but especially the wetted parts with original spare parts 6 Reassemble the fl...

Page 114: ... dust deposits and dirt If necessary clean the outer surfaces as described in Ä Chapter 6 1 Machine care on page 106 Operating person daily Audible check for smooth running In the event of a malfunction suitable measures as described in Ä Chapter 5 5 Malfunctions on page 95 Operating person Visual check for leaks including overflow check at the ventilation opening of the intermediate chamber Repla...

Page 115: ...all safety notes warnings and operating instructions If necessary replace damaged signs or stickers immediately Operating person biannually Checking the quality of the quench fluid Replace quench fluid cf Ä Chapter 6 2 2 Lubricant fill level and changing the lubricants on page 116 Replace seals if necessary in accordance with Ä Chapter 6 3 4 Replacing the mechanical seal on page 149 Operating pers...

Page 116: ... chamber and thus intruding on the process itself the quench fluid must be compatible with the medium in addition to the other materials especially with the material of the O rings NOTE Behavior of the quench fluid The level of quench fluid may not drop below the minimum indi cated on the level indicator The quench fluid can rise to the rim of the fill hole due to its function and depending on the...

Page 117: ...hen handling oil grease and other chemical substances pay attention and adhere to the applicable regulations and safety data sheets issued by the respective manufacturer relating to storage handling correct use and disposal Comply with the legal obligations regarding waste avoidance and the proper recycling disposal of waste during all work The intervals for changing the lubricants can vary signif...

Page 118: ...vel and changing the lubricants in drive components 2 In accordance with the maintenance and inspection plan see Ä Chapter 6 2 1 Maintenance and inspection plan on page 114 or more often depending on the operating con ditions check the oil level and oil quality of the gear unit on the oil sight glass and the level and quality of the quench fluid Use an oil dipstick when necessary Optimum fill leve...

Page 119: ...e safety instructions detailed in Ä Chapter 2 12 Safety instructions for maintenance and rectifying mal functions on page 30 Shut down the Börger machine and downstream and upstream system components as described in Ä Chapter 5 3 Down times on page 93 Secure the Börger machine against unauthorized or uncon trolled reactivation as described in Ä Chapter 2 7 Securing the machine against restart on p...

Page 120: ...with the screw plug Personnel n Mechanics Protective equip ment n Occupational safety clothing chemical resistant n Safety shoes n Safety gloves chemical resistant n Safety goggles Change the lubricants according to the following description after approximately 10 000 operating hours or earlier depending on the operating conditions or after two years whichever occurs first Change the lubricants ea...

Page 121: ...m the drain hole and drain the lubricant 4 Tightly close the drain hole 5 Remove the closure from the fill hole for filling 6 Fill the lubricant up to the optimum fill level having regard to the information in Ä Chapter 9 8 Lubricant list on page 187 7 Properly close the fill hole with the closure removed previ ously If the breather had to be removed reinstall it with the opening facing downwards ...

Page 122: ...prox Intermediate chamber approx FL 1036 2 4 l 0 634 gal M5 M6 turned 90 4 8 l 1 270 gal 518 3 4 l 0 898 gal 776 3 4 l 0 898 gal 1036 2 4 l 0 634 gal Maintenance and Repairs BA Classic FL_en US 03 05 2018 www boerger de www boerger com 122 ...

Page 123: ... safety clothing chemical resistant n Safety shoes n Safety gloves chemical resistant n Safety goggles Special tool n Tools general Read and follow the safety instructions detailed in Ä Chapter 2 12 Safety instructions for maintenance and rectifying mal functions on page 30 Shut down the Börger machine and downstream and upstream system components as described in Ä Chapter 5 3 Down times on page 9...

Page 124: ...ed parts for wear and only reuse them if they are undamaged 3 Only replace worn components seals screws nuts etc but especially the wetted parts with original spare parts according to the following instructions NOTE Assembly drawing spare parts list Observe the assembly drawing of the Börger machine Ä Chapter 9 3 Assembly drawing on page 175 Observe the spare parts list of the Börger machine Ä Cha...

Page 125: ...afety goggles Special tool n Tools general All parts on the Börger machine that are subject to wear are accessible after the quick release cover has been removed Read and follow the safety instructions detailed in Ä Chapter 2 12 Safety instructions for maintenance and rectifying mal functions on page 30 Shut down the Börger machine and downstream and upstream system components as described in Ä Ch...

Page 126: ...e of residual pressure 1 Opening the quick release cover Use a suitable cover to prevent the medium from spouting out 2 Place a drip pan underneath 3 Loosen the four ring nuts 1 uniformly by approx 5 mm 20 using a wrench 4 Initially only open the cover 2 at the bottom 6 on standing versions by a small gap approx 5 mm 20 to allow all residual pressure to escape and catch any medium that spouts out ...

Page 127: ...laced 13 Closing the quick release cover Attach the cover side casing protection plate 3 14 Push the quick release cover 2 over the stud screws 5 and fasten it with the ring nuts 1 15 Tighten the ring nuts 1 crosswise with uniform strength using a wrench Take care not to damage the O ring 4 or to push it out of position Make sure that the ring nuts 1 are fastened tight enough so they cannot be loo...

Page 128: ...emoving and replacing single piece rotors is described below Maintaining the MIP rotors with lobe tips is described in the next chapter Type A Dual lobe linear Polymers Pos 9 4 in the spare parts list Type D Tri lobe screw profile Steel stainless steel Pos 9 7 in the spare parts list Type D Tri lobe screw profile Polymers Pos 9 7 in the spare parts list Type I Optimum rotor Dual lobe screw profile...

Page 129: ...ctions detailed in Ä Chapter 2 12 Safety instructions for maintenance and rectifying mal functions on page 30 Shut down the Börger machine and downstream and upstream system components as described in Ä Chapter 5 3 Down times on page 93 Secure the Börger machine against unauthorized or uncon trolled reactivation as described in Ä Chapter 2 7 Securing the machine against restart on page 24 To the e...

Page 130: ... g a lint free cloth 2 Loosen the hexagon socket head cap screws 1 using a hex agon socket wrench then remove them 3 With polymer rotors Linear polymer rotors Screw the rotor puller W into the bore of the respective rotor and remove the rotor from the carrier shaft W Polymer screw rotors Screw one rotor puller W into each rotor and remove the rotors in pairs by pulling them from the carrier shaft ...

Page 131: ...res of the suitable auxiliary puller Z For linear rotors Screw the rotor puller W into the center bore of the auxiliary puller Z and then remove the rotor from the carrier shaft W For screw rotors Screw one rotor puller W into each auxiliary puller Z and remove the rotors in pairs by pulling them from the carrier shafts W in alternate uniform steps 5 Thoroughly clean all parts and the pump chamber...

Page 132: ...ng of the parallel keys 6 in the carrier shafts W Ä Chapter 6 3 4 Replacing the mechanical seal on page 149 NOTICE Risk of material damage if the rotating seal holding bushes are adjusted incorrectly Adjust the rotating seal holding bushes by means of the special tool Multitool M as described in Ä Chapter 6 3 4 Replacing the mechanical seal on page 149 If the rotating holding bush with thread is n...

Page 133: ...h the new rotors For screw rotors Attach the rotors uniformly in pairs one clockwise and one counter clockwise screw rotor each NOTE Optimum rotors can also be inserted one after the other For polymer rotors pay attention to the exact positioning so that the rubber coating is not damaged 13 Rotate the shafts so that the parallel keys 6 are at 12 o clock 14 Insert the rotor with counter clockwise s...

Page 134: ...isk 3 with the O ring 4 correctly fitted into the groove so that the recess points towards the parallel key 6 Use new sealing washers 2 for the rotor fastening screws 1 18 With Premium polymer rotors Use new O rings 9 Fit the O rings 9 onto the rotor fastening screws 8 which have also been replaced if necessary Ensure that each O ring 9 is correctly fitted into the O ring groove of the rotor faste...

Page 135: ...o the pump casing 21 Attach the cover side casing protection plate and quick release cover in accordance with Ä Chapter 6 3 2 Opening and closing the quick release cover on page 125 22 Before releasing the rotary lobe pump check once again that it runs smoothly by switching the drive on briefly If correct true running is not obtained the cause must be determined and the installation must be correc...

Page 136: ... MIP rotors is described below In case of MIP rotors which consist of a steel or stainless steel rotor body and removable lobe tips made from materials compat ible with the pumped medium only the lobe tips must be replaced on a regular basis in the event of wear The complete MIP rotors must only be replaced in in exceptional cases Screw rotors Removing and replacing the MIP lobe tips Maintenance a...

Page 137: ...ge 8 Screws 9 Lobe tip two parts in case of FL1036 10 Rotor body NOTICE Risk of material damage when using wetted parts made of non suitable material Compare the quality symbol b on the lobe tips that describes the material with the data sheet Only use lobe tips made from suitable materials Maintenance and Repairs BA Classic FL_en US 03 05 2018 www boerger de www boerger com 137 ...

Page 138: ... n Occupational safety clothing chemical resistant n Safety shoes n Safety gloves chemical resistant n Safety goggles Special tool n Torque wrench n Slide hammer Read and follow the safety instructions detailed in Ä Chapter 2 12 Safety instructions for maintenance and rectifying mal functions on page 30 Shut down the Börger machine and downstream and upstream system components as described in Ä Ch...

Page 139: ...ior of the Börger machine as described in Ä Chapter 6 1 3 Cleaning the inside on page 111 1 In case of screw rotors move the first lobe tip to be removed into a non meshed position A B C or D by rotating the car rier shaft clockwise using a hexagon socket wrench or ratchet 2 Block the carrier shafts by clamping an object with no sharp edges between the rotors e g a lint free cloth 3 Remove the T p...

Page 140: ...at the procedure until all lobe tips 9 have been removed 10 Check the rotor bodies 10 11 for wear Replace the rotor bodies 10 11 in the event of significant wear according to Ä Removing and replacing the MIP rotors on page 144 11 Loosen the respective screws 8 which fasten the clamping part 5 onto a lobe tip 9 12 Thoroughly clean the removed parts before reusing them 13 Check the clamping parts 5 ...

Page 141: ...osed to be installed into a suit able position not meshed and not touching the casing 18 Push the lobe tips 9 onto the rotor body 10 but do not fully insert the lobe tips 9 yet 19 Hand tighten the respective hexagon socket head cap screw 3 20 Bring the respective lobe tip 9 into the correct position by tapping it lightly with a plastic mallet for steel stainless steel lobe tips and a rubber mallet...

Page 142: ...ted too deep If the lobe tips cannot be aligned flush remove the rotors according to Ä Removing and replacing the MIP rotors on page 144 and check the position of the rotating holding bush according to Ä Chapter 6 3 4 Replacing the mechanical seal on page 149 If necessary assemble the rotors outside of the pump casing in such a way that the lobe tips at the front and rear are flush with the rotor ...

Page 143: ...he rotors can be coated with liquid e g soft soap for the smooth running check When dry polymer rotors can only be rotated with a cer tain degree of force as they are positioned close to the pump casing 26 Attach the cover side casing protection plate and quick release cover in accordance with Ä Chapter 6 3 2 Opening and closing the quick release cover on page 125 27 Before releasing the rotary lo...

Page 144: ... 4 O ring of cover disk 5 Rotor body 6 Lobe tip 7 O ring of rotating holding bush 8 Parallel key 9 Grub screws W Carrier shaft Removing and replacing the MIP rotors Maintenance and Repairs BA Classic FL_en US 03 05 2018 www boerger de www boerger com 144 ...

Page 145: ...damage due to insufficient or excessive pre tension of mechanical seals Risk of consequential damage if the rotating seal holding bushes are installed incorrectly The pre tension on the seal faces required for a correct seal is generated by the correct setting of the rotating holding bush Do not unscrew the rotating seal holding bush too far Do not screw in the rotating seal holding bush too far R...

Page 146: ... Block the carrier shafts by clamping an object with no sharp edges between the rotors e g a lint free cloth 4 Loosen the hexagon socket head cap screws 1 using a hex agon socket wrench then remove them 5 In each case remove the sealing washer 2 6 In each case remove the cover disk 3 and O ring 4 using a suitable hook or two slotted screwdrivers 7 For rotors with threaded bores see Fig 10 screw th...

Page 147: ...the material with the data sheet of your Börger machine Use only rotors made from suitable materials and of the correct type 17 Attach the rotors or rotor bodies one after the other If screw rotors are reattached without any changes after the mechanical seals have been replaced pay attention to the position of the rotor body tip without the lobe tip see figure on left so that both rotors can be at...

Page 148: ...obtained the cause must be determined and the installation must be corrected NOTE Smooth running Smooth running means a uniform trouble free true run ning concentricity without any blocking Providing the pumped medium and materials used allow this the rotors can be coated with liquid e g soft soap for the smooth running check When dry polymer rotors can only be rotated with a cer tain degree of fo...

Page 149: ...mical resistant n Safety shoes n Safety gloves chemical resistant n Safety goggles Special tool n Tools general n Multitool M Read and follow the safety instructions detailed in Ä Chapter 2 12 Safety instructions for maintenance and rectifying mal functions on page 30 Shut down the Börger machine and downstream and upstream system components as described in Ä Chapter 5 3 Down times on page 93 Main...

Page 150: ...diate chamber following a leak in the mechanical seal in order to remove all medium deposits from the chamber and from in front of the lip seals 6 To do this flush a suitable liquid water if appropriate through the fill hole with the drain open see Ä Chapter 3 1 7 Designs mounting positions on page 42 Also refer to Ä Chapter 9 8 Lubricant list on page 187 for cleaning 3 Open the quick release cove...

Page 151: ...emaining in the Börger machine using a suitable tool e g screwdriver 9 Clean the O ring seats with a suitable agent that is compat ible with the seal material quench fluid and medium e g alcohol based industrial cleaner 10 Thoroughly clean all parts and the working chamber of the machine before reinstalling removed parts 11 Check all removed parts for wear and only reuse them if they are undamaged...

Page 152: ...se on the O rings of mechanical seals Material damage resulting from loss of seal function The O rings of a mechanical seal must be installed without oil or grease NOTE Spray cleaner degreaser Generally the seal faces equipped with O rings can be inserted dry In order to ensure that they are free of grease and to aid insertion the O rings can be sprayed lightly depending on their resistance with a...

Page 153: ...bushes are installed incorrectly First install one rotating holding bush with new mechan ical seal completely according to the following descrip tion and secure the bush with the parallel key before installing the second rotating holding bush with new mechanical seal on the second shaft If the rotating holding bush with thread is not secured when the shafts are turned the position of the holding b...

Page 154: ...Undersize U pump casing depth length of stainless steel rotor 0 5 mm 0 2 inch Half undersize U 2 undersize U 2 0 25 mm 0 1 inch NOTE As a result the rotating seal holding bush must be unscrewed by half the undersize U 2 0 25 mm 0 1 inch Old Rotor rubber coated New Rotor steel stainless steel with edge Setting No resetting of the rotating seal holding bush required Rotating seal holding bush flush ...

Page 155: ... half the undersize Rotating seal holding bush flush with casing protection plate Old Rotor rubber coated New Rotor steel stainless steel without edge Setting Unscrew the rotating seal holding bush by half the undersize NOTICE Risk of material damage due to insufficient or excessive pre tension of mechanical seals Risk of consequential damage if the rotating seal holding bushes are installed incor...

Page 156: ...rst grove is aligned with the keyway see step 20 20 Insert the parallel key 9 so that it fits into the groove of the rotating seal holding bush 2 and the keyway of the shaft 3 The side of the parallel key must fit into the rotating seal holding bush with the nib upwards If the parallel key consists of two or three pieces and there is a straight front on one of the parallel keys then this must poin...

Page 157: ...placement on page 128 depending on the rotor type 24 Check that the rotors run smoothly If a rotating seal holding bush is screwed in too far the rotors rub against the gear side casing protection plate and the shaft can only turn with difficulty Remove the rotors and unscrew the relevant rotating seal holding bush by 1 12th of a turn one groove If a rotating seal holding bush was not screwed in f...

Page 158: ...ning is not obtained the cause must be determined and the installation must be corrected 27 Fill the intermediate chamber and close the fill hole in accord ance with Ä Chapter 6 2 2 Lubricant fill level and changing the lubricants on page 116 Maintenance and Repairs BA Classic FL_en US 03 05 2018 www boerger de www boerger com 158 ...

Page 159: ...afety instructions for maintenance and rectifying mal functions on page 30 Shut down the Börger machine and downstream and upstream system components as described in Ä Chapter 5 3 Down times on page 93 Secure the Börger machine against unauthorized or uncon trolled reactivation as described in Ä Chapter 2 7 Securing the machine against restart on page 24 To the extent necessary amply secure the su...

Page 160: ... turned 90 to ensure the clamping parts 3 cannot fall into the pipe when they are loosened 3 Loosen the clamping parts 3 used to fix the casing liners 5 in the pump casing To do this loosen the hexagon socket head cap screws 1 above and below the inlet and outlet openings The clamping parts 3 may not always loosen easily due to deposits of the pumped medium In most cases hitting the screw head lig...

Page 161: ... at the rear wall You can use a plastic mallet to aid insertion without damaging the casing liners 5 The complete front edge of the casing liner 5 must be flush with the pump casing 11 Secure the casing liners 5 by tightening the opposite hex agon socket head cap screws 1 alternately and uniformly with the appropriate torque see Ä Clamping part torque on page 162 12 If you have removed the rotors ...

Page 162: ...r on page 125 FL 518 M12 steel screws 10 9 100 Nm 885 in lbs M12 stainless steel screws A4 70 A5 70 60 Nm 531 in lbs FL 776 FL 1036 M10 steel screws 10 9 50 Nm 443 in lbs M10 stainless steel screws A4 70 A5 70 40 Nm 354 in lbs Clamping part torque Maintenance and Repairs BA Classic FL_en US 03 05 2018 www boerger de www boerger com 162 ...

Page 163: ...oggles Special tool n Tools general n W1 Sealing compound Read and follow the safety instructions detailed in Ä Chapter 2 12 Safety instructions for maintenance and rectifying mal functions on page 30 Shut down the Börger machine and downstream and upstream system components as described in Ä Chapter 5 3 Down times on page 93 Secure the Börger machine against unauthorized or uncon trolled reactiva...

Page 164: ...ype 3 Unscrew the countersunk screws 2 from the gear side casing protection plate standard M8 with Torx head 4 Screw two sufficiently long M6 screws into the jacking threads 4 to loosen the respective half casing protection plate then remove the plate 5 Clean any sealing compound from the rear wall of the machine casing 6 Apply sealing compound W1 to that side of the new casing protection plate wh...

Page 165: ...thing chemical resistant n Safety shoes n Safety gloves chemical resistant n Safety goggles Special tool n Tools general Read and follow the safety instructions detailed in Ä Chapter 2 12 Safety instructions for maintenance and rectifying mal functions on page 30 1 Check all screws that have been loosened previously for firm seat 2 Check whether all safety devices and covers that have been removed...

Page 166: ...ic requirements of the operator so that not all questions can be fully answered in a general operating manual If you have any questions please contact Börger customer service We will be happy to help We would also be grateful to receive feedback on any errors or unclear passages in this operating manual This will help us to improve and develop this document and to offer you and all of our customer...

Page 167: ...able regulations and safety data sheets issued by the respective manufacturer relating to storage handling correct use and disposal Comply with the legal obligations regarding waste avoidance and the proper recycling disposal of waste during all work 7 2 Oil oily waste and grease Oil oily waste and grease pose a significant risk to the environ ment Therefore disposal of such materials must be hand...

Page 168: ...st be disposed of separately Electrical and electronic waste must not be disposed of with domestic waste Only dispose of electrical or electronic waste according to the legal requirements through authorized waste disposal compa nies authorities e g recycling plants 7 6 Final decommissioning Check which materials can be recycled and make the appro priate arrangements Disposal BA Classic FL_en US 03...

Page 169: ... cooler may be necessary if the motor frequency is set very low 8 2 Monitoring equipment 8 2 1 Dry run protection Long dry run periods i e operation without pumped medium should be avoided This especially applies to rotary lobe pumps with rubber coated rotors Components on the rotary lobe pump are damaged when frictional heat is generated In processes in which dry running cannot be fully excluded ...

Page 170: ...nd all attachment parts There is also a risk of leakage and subsequent risks to per sonnel and the environment depending on the medium Pressure monitoring devices of different manufacturers offer pro tection from damage due to overpressure The Börger machine or the system can thus be switched off when a preset pressure is exceeded or other measures for reducing the pressure can be carried out 8 2 ...

Page 171: ... be used for dry run protection depending on the version 8 3 Auger feed An auger feed with a feed hopper at the inlet of the Börger machine allows non flowing or hardly flowing media that are just able to be pumped to be conveyed in certain cases Fig 13 Example float switch Accessories BA Classic FL_en US 03 05 2018 www boerger de www boerger com 171 ...

Page 172: ... manufacturer if in doubt The following wear parts list includes the quantity designation and position number of the elements that are replaced during the corre sponding repair work Also observe the assembly drawing according to Ä Chapter 9 3 Assembly drawing on page 175 and the spare parts list according to Ä Chapter 9 2 Wear parts on page 172 Machine type version and the corresponding materials ...

Page 173: ...ece s 64 Hexagon socket head cap screw for fastening the rotor to the shaft 2 piece s 74 Sealing washer 0 2 piece s Replacing the mechanical seals Pos no Designation Quantity Unit 15 Mechanical seal 2 seal faces 2 O rings 2 piece s 30 O ring for quick release cover 1 piece s 31 O ring for rotating holding bush 2 piece s 32 O ring for cover disk 0 2 piece s 74 Sealing washer 2 piece s Replacing the...

Page 174: ...ers Simply quote the type code and serial number on the name plate of the Börger machine when ordering Börger will then obtain the information for the appropriate spare parts for you from the production documents of your machine Record all modifications made to the equipment after the initial delivery such as changes to rotating components type material or seals In order to avoid incorrect deliver...

Page 175: ...sembly drawing The assembly drawing shows the positions of the spare parts as described in Ä Chapter 9 4 Spare parts list on page 177 Appendix BA Classic FL_en US 03 05 2018 www boerger de www boerger com 175 ...

Page 176: ...9 3 1 Rotary lobe pump Appendix BA Classic FL_en US 03 05 2018 www boerger de www boerger com 176 ...

Page 177: ...mate rial damage Only use suitable spare parts Always contact the manufacturer if in doubt The spare parts list is universal The positioning of the parts can be seen in the assembly drawing The parts used in your Börger machine are defined according to the type designation and all the additional specifications in the data sheet Appendix BA Classic FL_en US 03 05 2018 www boerger de www boerger com...

Page 178: ...Clamping base Clamping wedge Clamping wedge 6 6 12 9 2d Hexagon socket head cap screw DIN EN ISO 4762 for clamping part pos 9 2c 6 6 12 9 2e Hexagon socket head cap screw DIN 6912 for clamping base 12 12 24 9 2f T plug for lobe tip position 9 2b 6 6 6 9 2g Spacer for lobe tip position 9 2b 6 9 4 Rotor dual lobe linear 2 9 5 Optimum rotor dual lobe screw profile ccw Optimum rotor dual lobe screw pr...

Page 179: ... 965 8 8 8 53 Stud screw DIN 939 4 4 4 55 Dowel pin DIN EN ISO 8735 form A 2 2 2 60 Lifting eye bolt M20 DIN 580 1 1 1 62 Parallel key for drive shaft DIN 6885 1 form A 0 1 2 0 1 2 0 1 2 63 Parallel key DIN 6885 1 modified 2 64 Hexagon socket head cap screw DIN 6912 2 2 2 65 Oil sight glass 1 1 1 1 66 Screw plug DIN 908 2 2 2 67 Breather system 1 1 1 68 Grub screw EN ISO 4027 4 4 4 69 Screw plug D...

Page 180: ...e parts with voltage ratings up to 1000V AC or 1500V DC Products designed and manufactured according to this standard contribute to the user s safety provided they are used by qualified electricians in compliance with the safe working practices and the operating manual if applicable Tools general Various hexagon socket wrenches and or sockets for hexagon socket head cap screws Various open end rin...

Page 181: ... holding bushes Push in tool B for mechanical seals Remove handle Slide hammer For pulling out and removing deep set parts special adaptations allow versatile use for other parts as well The parts are pulled off by striking them with the slide hammer Torque wrench A torque wrench is a hand held fastening tool with which a defined torque can be applied to a connecting element screw or nut so as to ...

Page 182: ...e used for tri lobe rotors with cover disk 2x for screw rotors W1 Sealing compound 50 ml 0 013 gal tube 200 ml 0 053 gal tube Z auxiliary puller dual lobe The Z auxiliary puller in combination with the W rotor puller and two suitable screws not included in the scope of supply is to be used for dual lobe rotors with cover disk 2x for screw rotors Z auxiliary puller tri lobe The Z auxiliary puller i...

Page 183: ...3 14 x 9 x 93 mm 0 55 x 0 35 x 3 66 14 x 9 x 207 mm 93 114 mm 0 55 x 0 35 x 8 15 3 66 4 49 FL 776 14 x 9 x 146 mm 93 53 mm 0 55 x 0 35 x 5 75 3 66 2 09 14 x 9 x 156 mm 93 63 mm 0 55 x 0 35 x 6 14 3 66 2 48 14 x 9 x 218 mm 93 125 mm 0 55 x 0 35 x 8 58 3 66 4 92 FL 1036 14 x 9 x 207 mm 93 144 mm 0 55 x 0 35 x 8 15 3 66 4 49 14 x 9 x 218 mm 93 125 mm 0 55 x 0 35 x 8 58 3 66 4 92 14 x 9 x 223 mm 93 70...

Page 184: ... equipment installed correctly connected and functions checked 7 Electrical connections and grounding OK direction of rotation of drive shaft correct 8 Oil level in drive OK transport lock removed from breather system if present 9 Oil level in the gear unit of the Börger machine OK in M2 mounting position screw plug replaced by breather system 10 Fluid level in the intermediate chamber OK breather...

Page 185: ...XXXX 1 X Year of manufacture from 2017 are in compliance with all relevant provisions of the Machinery Directive 2006 42 EC The machines are further in compliance with all provisions of the Electrical Equipment 2014 35 EU and Electromagnetic Compatibility 2014 30 EU Directives The following harmonized standards were applied DIN EN ISO 13857 DIN EN 809 DIN EN 12162 Name and address of the authorize...

Page 186: ...4 35 EU and Electromagnetic Compatibility 2014 30 EU Directives The incomplete machine may only be put into operation when it has been determined that the machine in which the incomplete machine is to be installed is in compliance with the provisions of the Machinery Directive 2006 42 EC The manufacturer is obligated to electronically submit the specific documentation for the incomplete machine to...

Page 187: ...bstances Inappropriate handling of environmentally hazardous substances especially incorrect disposal can cause significant damage to the environment Especially water polluting materials such as grease and lubri cating oil must not pollute the soil or enter the sewage system during installation repair and maintenance work These materials must be collected stored transported and disposed of in suit...

Page 188: ...t specified in the data sheet The lubricants used must meet the quality standards as detailed above Otherwise the warranty supplied by Börger GmbH is void Deviations are only permitted following consultation with Börger GmbH If the actual operating conditions on or after commissioning deviate from those specified in the order then a change of lubricant must be considered Any such actions must be a...

Page 189: ... then the used oil must be completely removed from the gear unit In this case the gear unit must be flushed carefully with the new oil Gear oils must not become contaminated with other substances including any residue from cleaning agents e g petrol Therefore flushing with petrol or other cleaning agents is not permitted 9 8 2 Buffer fluid Any fluids with good lubricant qualities that do not react...

Page 190: ...thanol are unsuitable as lubricants The lubricants used must meet the quality standards as detailed above NOTICE Risk of material damage when using wrong lubricants Versions for special applications and or with special sealing com pounds may require special lubricants Filling with these lubricants is approved tested specifically for the supplied version and is indicated in the data sheet In such c...

Page 191: ... 200 C 392 F can be used in the buffer The use of oils in contact with EPDM is prohibited In these cases an alternative lubricant must be selected for the buffer or the circu lation system All gear oils and buffer fluids used in the food and feed industry must be food safe e g NSF H1 NOTE Special lubricants can be supplied upon request In this case the agreed limits apply All values specified are ...

Page 192: ...ype Viscosity T 40 C 104 F Aral Degol BAB 220 BP Enersyn HTX 220 Castrol Alphasyn T 220 Chevron Tegra Syn Synthetic EP 220 Mobil Mobilgear SHC 630 220 Lukoil Stello S 220 Shell Omala S4 GX 220 Texaco Pinnacle EP 220 Petronas Gear Syn IG 220 Lubriplate Syn Lube 220 Total Carter SY 220 Food safe lubricants Manufacturer Designation Type Viscosity T 40 C 104 F Notes Castrol Optileb GT 220 NSF H1 Shell...

Page 193: ...40 C 104 F Aral Degol BAB 68 BP Enersyn HTX 68 Castrol Alphasyn HTX 68 Chevron Cetus PAO 68 Mobil Mobilgear SHC 626 68 Lukoil Stello S 68 Shell Omala S4 GX 68 Texaco Cygnus PAO 68 Petronas Gear Syn IG 68 Lubriplate Syn Lube 68 Lubricants suitable for EPDM seals Manufacturer Designation Type Viscosity T 40 C 104 F Application temperature LANXESS Dow Propylene glycol pure 19 5 up to 100 C 212 F LANX...

Page 194: ...ants for circulation systems Manufacturer Designation Type Viscosity T 40 C 104 F Application temper ature Notes LANXESS Dow Propylene glycol pure 19 5 up to 100 C 212 F USP EP LANXESS Dow Water Glycerin 70 30 1 4 up to 60 C 140 F USP EP Klüber Paraliq P12 22 up to 60 C 140 F medicinal white oil NSF H1 Klüber Klüberoil 4 UH1 15AF 15 up to 110 C 230 F NSF H1 ATEX compatible ignition temperature 200...

Page 195: ... M3 standing upside down 5 6 1 48 3 8 1 00 M5 turned 90 4 8 1 27 3 4 0 90 M2 vertical 9 0 2 38 4 2 1 11 FL 1036 FL 1540 M1 M3 standing upside down 5 6 1 48 2 4 0 63 M5 turned 90 4 8 1 27 2 4 0 63 M2 vertical 9 0 2 38 2 4 0 63 EL M1 M3 standing upside down 16 0 4 23 3 3 0 87 M5 turned 90 12 5 3 30 3 3 0 87 M2 vertical 24 5 6 47 3 3 0 87 XL M1 M3 standing upside down 26 5 7 00 13 0 3 43 M5 turned 90...

Page 196: ...diate chamber Design Code Design Description approx l approx gal approx l approx gal M1 standing upside down 16 0 4 23 3 3 0 87 Submersible mixer Gear unit Intermediate chamber B MX Size approx l approx gal approx l approx gal New 9 4 0 1 06 0 2 0 05 3 4 0 1 06 0 2 0 05 18 4 5 1 19 0 2 0 05 22 4 5 1 19 0 2 0 05 Old 9 2 5 0 66 0 1 0 025 3 4 0 1 06 0 1 0 025 18 4 0 1 06 0 1 0 025 22 does not apply d...

Page 197: ... avoid incorrect deliveries always quote all modifica tions made when ordering lubricants Article number Lubricants Abbreviation DAD 034 Gear oil CLP 220 DAD 030 Synthetic gear oil CLP 220 SYN DAD 032 Food safe gear oil Castrol Optileb GT 220 DAD 035 Hydraulic oil HLP 68 DAD 031 Synthetic gear oil CLP 68 SYN DAD 033 Food safe hydraulic oil Castrol Ortlieb HY 68 DAD 072 Medicinal white oil Castrol ...

Page 198: ...erschmierstoff für Gleichlaufgetriebe Special lube for timing gear PETRO CANADA PURITY FG SYNTHETIC EP GEAR FLUID 220 Sonderschmierstoff für Zwischenkammer Special lube for intermediate chamber PETRO CANADA PURITY FG WO WHITE MINERAL OIL 68 Sonderschmierstoff für Umlaufsystem Special lube for circulation system Bemerkungen Remarks Change of lubricant according to specifications listed in operating...

Page 199: ...ating manuals for special versions are also part of this operating manual 9 10 Supplier documentation You must completely read the separate supplier documentation and consider it accordingly Appendix BA Classic FL_en US 03 05 2018 www boerger de www boerger com 199 ...

Page 200: ...ist for commissioning 91 Cleaning the inside 111 Commissioning 89 Checks 79 Complete 91 Complete commissioning 91 Components 37 Conductivity sensor 170 Connection electrical 73 hydraulic 73 PTO shaft 73 Construction Accessories 47 Casing 38 Components 37 Designs 40 Drive options 46 Intermediate chamber 40 Mounting positions 40 Options 47 Pipe connections 44 Quench 40 Quick release cover 38 Shaft s...

Page 201: ...stallation aid 180 Instruction 10 Interim storage 61 Intermediate chamber 26 40 60 Introduction of the operating manual 8 K Key to the signs 13 Key to the symbols 13 L Labeling 27 Level control 171 Level monitor 171 Lubricant list 116 Börger gear units 188 Buffer fluid 189 Customer approval special lubricants 187 Lubricant orders 197 Oil properties 190 Oil types 188 Special lubricants 187 Lubrican...

Page 202: ...89 Continuous operation 92 Downtimes 18 Emergency shut down 94 Malfunctions 95 Test run 90 Operator Information for the operator 9 Marking 29 Noise protective equipment 36 Signs 29 Training and instruction 10 Overpressure protection 170 P Parallel keys 183 Performance data 52 Personal protective equipment 19 Personnel 20 Pipe connections 44 Points of contact 3 Positioning Service spaces 66 PPE 19 ...

Page 203: ...hooting 24 30 Safety equipment 18 Coupling guard 26 Intermediate chamber 26 Monitoring equipment 169 Securing the machine against restart 24 30 Service 3 Shaft seal 40 Signs 27 Skills 20 Spare parts list 42 Installation aid 180 Tools 180 Spare parts orders 3 Special dangers 36 Storage 55 58 Storage conditions 58 Subsidiaries 2 Supplier documentation 199 Symbols In the manual 13 Markings on the mac...

Page 204: ...V belt tension 72 W Wear parts 106 Index BA Classic FL_en US 03 05 2018 www boerger de www boerger com 204 ...

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