Crane ELRO IP 100 Installation And Operation Manual Download Page 6

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Peristaltic Pumps Series IP 100-800

Page

Maintenance ............................................................................................................ 19

5.1

Cleaning ................................................................................................................................19

5.1.1

Cleaning pumps for food applications ................................................................................... 20

5.1.2

Selection of pumping hoses .................................................................................................. 20

IP 100/200

5.2

Replacing the pumping hose ................................................................................................. 21

5.2.1

Removing the old pumping hose ........................................................................................... 21

5.2.2

Inspecting the inside of the pump ......................................................................................... 22

5.2.3

Installing the new pumping hose ........................................................................................... 22

5.3

Conversion suction side “top” to suction side “bottom” ......................................................... 23

5.4

Pump conversion for different pumping pressure .................................................................. 23

5.4.1

Installation of a full fabric hose .............................................................................................. 24

IP 300/500

5.5

Replacing the pumping hose ................................................................................................. 25

5.5.1

Removing the old pumping hose ........................................................................................... 25

5.5.2

Inspecting the inside of the pump ......................................................................................... 26

5.5.3

Installing the new pumping hose ........................................................................................... 26

5.6

Conversion suction side “top” to suction side “bottom” ......................................................... 29

5.7

Pump conversion for different pumping pressure .................................................................. 29

5.7.1

Installation of a full fabric hose .............................................................................................. 30

IP 400

5.8

Replacing the pumping hose ................................................................................................. 31

5.8.1

Removing the old pumping hose ........................................................................................... 31

5.8.2

Inspecting the inside of the pump ......................................................................................... 32

5.8.3

Installing the new pumping hose ........................................................................................... 32

5.9

Conversion suction side “top” to suction side “bottom” ......................................................... 34

5.10

Pump conversion for different pumping pressure .................................................................. 34

5.10.1

Installation of a full fabric hose .............................................................................................. 35

Summary of Contents for ELRO IP 100

Page 1: ...lt of Crane Pumps Systems Inc constant product improvement program product changes may occur As such Crane Pumps Systems Inc reserves the right to change product without prior written notification PUMPS SYSTEMS 420 Third Street P O Box 603 Piqua Ohio 45356 0603 USA Phone 937 773 2442 Fax 937 773 2238 www cranepumps com A Crane Co Company PUMPS SYSTEMS DISCONTINUED Parts may NOT be available ...

Page 2: ...ww cranepumps com RETURNED GOODS RETURN OF MERCHANDISE REQUIRES A RETURNED GOODS AUTHORIZATION CONTACT YOUR LOCAL CRANE PUMPS SYSTEMS INC DISTRIBUTOR Products Returned Must Be Cleaned Sanitized Or Decontaminated As Necessary Prior To Shipment To Insure That Employees Will Not Be Exposed To Health Hazards In Handling Said Material All Applicable Laws And Regulations Shall Apply 2 ...

Page 3: ...UMP Included with the pump shipment are the following documents 1 IP100 IP800 Installation and operating manual 2 Gear drive motor installation and operating 3 Pump parts breakdown with repair kit information NOTE Drive coupling needs to be checked for proper alignment after installation 3 ...

Page 4: ...4 ...

Page 5: ...and notes on safety 13 2 7 Maintenance work 13 2 7 1 Health and safety information on electric equipment 14 2 7 2 Health and safety information for work on pressure lines 14 2 7 3 Regulations and instructions on lubrication 15 2 8 Noise 15 3 Installation Instructions 16 3 1 Points to be observed before installation 16 3 2 Installation and connection 16 4 Operating Instructions 18 4 1 Points to be ...

Page 6: ...ull fabric hose 24 IP 300 500 5 5 Replacing the pumping hose 25 5 5 1 Removing the old pumping hose 25 5 5 2 Inspecting the inside of the pump 26 5 5 3 Installing the new pumping hose 26 5 6 Conversion suction side top to suction side bottom 29 5 7 Pump conversion for different pumping pressure 29 5 7 1 Installation of a full fabric hose 30 IP 400 5 8 Replacing the pumping hose 31 5 8 1 Removing t...

Page 7: ...Removing the old pumping hose 36 5 11 2 Inspecting the inside of the pump 37 5 11 3 Installing the new pumping hose 37 5 12 Conversion suction side top to suction side bottom 39 5 13 Pump conversion for different pumping pressure 39 5 13 1 Installation of a full fabric hose 41 6 Troubleshooting 42 ...

Page 8: ...d with the pump must have read this manual especially the chapter Safety before starting work This also applies to persons who work on the pump only occasionally e g for maintenance and cleaning work Each pump is subjected to stringent inspections and function tests before leaving the factory You should always bear in mind that the function long lifetime and optimal operational reliability of the ...

Page 9: ...ivery Faults resulting from the non compliance with the afore mentioned regulations and notes can only be rectified at the cost of the customer 1 2 Transport storage In order to avoid any problems you should check the delivered goods against the delivery note for completeness and correctness check pumps with drive units for availability of the instructions manual for the drive upon arri val of the...

Page 10: ...or the vacuum in the pump Fig 2 This additionally aids the restoring force of the hose to its original full cross section The IP series of peristaltic pumps work on the basis of a patented vacuum principle As the rotor turns air is pumped through an additional channel in the hose see cross section Fig 3 out of the upper area of the pump housing This generates a vacuum inside the sealed aluminium h...

Page 11: ... the hose with its outer rotor ends This process hermetically separates the suction from the pressure side Fig 4 The volume Fig 5 between both rotor ends is exactly half the displacement per revolution The rotation of the rotor displaces the product inside the hose towards the outlet port on the pressure side This generates a vacuum in the suction side each time the hose opens which ensures consta...

Page 12: ...ration and should always be complied with Strictly observe the operating instructions for the pump drive unit 2 Safety 2 1 General Make sure that the pump is installed in compliance with all applicable national safety regulations Always observe all applicable accident prevention instructions and implementing regulations The following precautions must be applied before performing maintenance work I...

Page 13: ... referring to instructions regula tions or work sequences which must be strictly complied with In this manual these symbols are used to highlight notes on possible dangers 2 7 Maintenance work Maintenance work must only be performed by qualified and specially instructed persons This applies particularly for all work on electric hydraulic and pneumatic equipment Keep unauthorized persons away from ...

Page 14: ...y unauthorized removal of covers unprofessional use of pump inadequate maintenance Before starting installation work on electrical equipment this equipment must be reliably de energized Cover non insulated live power lines and plug connections against unintended contact Electric components stored and not used for a longer period of time should be carefully inspected before use to ensure that the i...

Page 15: ...when the system is running As a measure to avoid injury all lubrication work should only be carried out using permitted and appropriate tools and working aids Rotating or mobile parts must be shut down and reliably secured against restarting before starting work Do not touch rotating parts and always keep a safe distance to avoid clothing or hair being caught Strict cleanliness is of utmost import...

Page 16: ...n 4 Check the pump arrangement to ensure that suction lift and discharge head are not exceeded Check also motor speed and power in HP kW The pump performance curves can be used to check the flow rate at a given speed 3 2 Installation and connection The pump unit must be installed and fastened on a level base of suffient load bearing capacity for the weight of the pump See foundation plan Fig 9 Fig...

Page 17: ...easily accessible Peristaltic pumps are variable displacement pumps which produce a pulsating product flow In order to prevent these pressure shocks from being transferred into the piping system both pressure and suction sides should be fitted with expansion joints Fig 10 As an additional measure to minimize pulsation the pressure pipe can be fitted with an active pulsation damper These must be ad...

Page 18: ... the motor These must be connected so that the motor is stopped when the switch is triggered 4 2 4 2 Commissioning The drive unit is to be started up in accordance with the respective operating instructions Check the lubrication of the drive unit Geared motor and regulating gears are filled for grease lubrication In case of oil lubrication the oil in the gear housing must be checked and if necessa...

Page 19: ...parts must be replaced 5 Maintenance Always observe the safety regulations in chapter 2 when performing maintenance work and conversions Check all lines and fittings regularly for leaks and externally visible damage Eliminate any faults immediately Peristaltic pumps of series IP require only little maintenance Ball bearings and radial seals in the pump neck are lifetime lubricated by the silicone ...

Page 20: ...ching scraping or brushing Minor dirt deposits such as layers of dust and fine deposits can be wiped off cleaned off with a vacuum cleaner removed with a brush or broom 5 1 1 Cleaning pumps for food applications CIP Clean in place The pumps can be cleaned manually after disassembly or in place CIP Consult the pump supplier for special application related cleaning procedures Do not touch pump or pi...

Page 21: ...g 13 and let the lubrication fluid run into the container 1 3 2 Fig 13 1 Cover fastening nuts 2 Oil filler bore with plug 3 Oil drain bore with plug 4 Unscrew 4 cover fastening nuts 1 Fig 13 take off cover and O ring and let the rest of the sliding fluid flow into the container 5 Unscrew both connecting sockets complete with retaining flange and hexagon tube nuts from the pump housing Fig 14 and p...

Page 22: ...pushing the hose so that the rotor can pull the pumping hose step by step into the pump housing Once the pumping hose has reached the opening on the pressure side of the pump housing switch off the pump and guide the pumping hose with a round steel bar through the opening in the pump housing do not use any tools with sharp edges Switch the pump on again for a short moment so that the correct insta...

Page 23: ...he retaining rings Then insert the connecting socket into the pumping hose and tighten the retaining flange evenly 6 Reinstall the drain plug 3 Fig 13 Fill with lubrication fluid 0 5 1 0 litres see techn data 7 Reinstall filler plug do not forget the seal ring 5 3 Conversion suction side top to suction side bottom The vacuum system needs to be changed for this purpose 1 Switch off the pump and sec...

Page 24: ... 116 145 psi 158 mm 6 22 inches 10 13 bar 145 188 4 psi 160 mm 6 30 inches 5 4 1 Installation of a full fabric hose Besides the operation with vacuum the pump can also be operated with a pumping hose without vacuum bore The installation procedure for a so called full fabric hose is identical with the procedure for a standard pumping hose Switch off the pump and secure it against restarting Then pr...

Page 25: ...ainer under the pump to catch the lubricating fluid Fig 19 1 Cover fastening nuts 2 Oil filling bore plug 3 Oil drain bore plug Danger or burning Before removing the pumping hose allow the pump to cool down to contact temperature 2 1 3 5 Unscrew both connecting sockets complete with retaining flange and hexagon tube nuts from the pump housing Fig 20 and pull both connecting sockets out of the pump...

Page 26: ...the rotor until a sliding shoe is positioned between both ends of the hose 2 Unhook the spring from the rotor Unlock the locking plate for the bolt and turn it to the side Pull out the bolt and remove the sliding piece Fig 23 The tapered pan may drop off the stud 1 2 Fig 24 3 Turn the rotor for 180 so that the hose is relieved from the second sliding piece 4 Pull the pumping house to the back out ...

Page 27: ...g hose has reached the opening on the pressure side of the pump housing switch the pump off and centre the hose with a round steel bar to guide it through the opening in the housing Do not use any tools with sharp edges 5 Switch the pump on again for a short moment so that the correct installation position can be reached Fig 27 The pumping hose is delivered in correct installation length The corre...

Page 28: ...ring 4 O ring 8 Slide a new O ring 4 over the hose and press it firmly into the respective groove in the housing 9 Slide the packs consisting of retaining ring 3 segment ring 2 and step ring 1 over the hose on suction and pressure side 10 Assemble the ventilation pipe on suction and pressure side Fig 21 wet slightly with lubricating fluid Make sure that the ventilation pipes are free of kinks or d...

Page 29: ...p cover see previous section Fig 31 3 Turn the rotor by hand until one of the sliding shoes Fig 31 is free 4 Adjust the gauge block to the desired tube gap pressure stage 5 Measure distance sliding piece pump housing X and compare with the following table 6 To adjust the tube distance loosen counter nut 1 and adjust the sliding piece to the desired distance adjustment of gauge block by turning adj...

Page 30: ...e identical x Gauge block to adjust the rotor gap 5 7 1 Installation of a full fabric hose Besides the operation with vacuum the pump can also be operated with a pumping hose without vacuum bore The installation procedure for a so called full fabric hose is identical with the procedure for a standard pumping hose Switch off the pump and secure it against restarting Then proceed as described in cha...

Page 31: ...ace a container under the pump to catch the lubricating fluid 3 Unscrew plugs 2 3 Fig 33 and let the lubricating fluid run into the container 4 Unscrew 4 cover fastening nuts 1 Fig 33 take off pump cover and O ring and let the Fig 34 3 1 2 5 Unscrew both connecting sockets complete with retaining flange and hexagon tube nuts from the pump housing Fig 34 and pull both connecting sockets out of the ...

Page 32: ... 6 Then remove the ventilation pipes from suction and pressure side Fig 35 Remove retaining ring segment ring step ring and O ring from the pumping hose Fig 36 7 Attach pump cover with O ring and tighten slightly with nuts Fig 36 5 8 3 Installing the new pumping hose 1 Attach the pump cover with a new O ring and tighten the nuts Fig 37 Slightly lubricate one end of the pumping hose with lubricatin...

Page 33: ...exactly in line The hose must not be twisted during installation If the hoses protrudes too far out of the pump housing on the pressure side it must be completely removed and reassembled again Fig 40 4 Completely assemble the connecting socket on the pressure side Start by assembling the new O ring to the step ring Fig 41 X 1 Retaining ring 2 O ring 1 2 Fig 41 Fig 42 Then assemble the segment ring...

Page 34: ...ert the ventilation pipe suction side into the small hose bore and lay it into the groove in the retaining ring narrow Fig 35 Insert the other end into the angle fitting and fasten it with the spigot nut 6 Replace the oil drain plug fill with lubricating fluid see chapter Technical Data for proper amount 7 Replace fill plug do not forget the seal ring 5 9 Conversion suction side top to suction sid...

Page 35: ... 3 7 Replace oil chain plug 8 Fill in lubricating fluid 9 Replace fill plug Pressure Diameter rotor 0 2 bar 0 29 psi 338 mm 13 31 inches 2 4 bar 29 58 psi 339 mm 13 35 inches 4 6 bar 58 87 psi 340 mm 13 39 inches 6 8 bar 87 116 psi 341 mm 13 43 inches 8 10 bar 116 145 psi 342 mm 13 46 inches 10 13 bar 145 188 4 psi 343 mm 13 50 inches When changing the rotor dimension use the same shims on both si...

Page 36: ...2 Place a clean container under the pump to catch the lubricating fluid 3 Unscrew plugs 2 3 Fig 46 and let the lubricating fluid run into the container 1 3 2 Fig 46 Unscrew 4 cover fastening nuts 1 Fig 46 take off pump cover and O ring and let the rest of the lubricating fluid flow out of the pump housing into the container Fig 47 4 Unscrew both connecting sockets complete with retaining flange an...

Page 37: ...be Fig 50 51 Fig 50 Design up to 2000 8 Pull the pumping hose out of the housing Fig 51 5 11 3 Installing the new pumping hose Before installing a new pumping hose turn the rotor so that no sliding tube is inside the hose area Fig 52 Fig 52 1 Fig 51 Design after 2000 5 11 2 Inspecting the inside of the pump 1 Before installing a new pumping hose clean the inside of the pump housing and check for d...

Page 38: ...installation 2 2 Pumping hoses are delivered in correct installation lengths The correct installation position is reached when the hose section protruding from the opening in the pump housing matches the non threaded part of the studs Fig 54 If the hoses protrudes too far out of the pump housing on the pressure side it must be completely removed and reassembled again Fig 55 1 Retaining ring 2 O ri...

Page 39: ...eplace the oil drain plug fill with lubricating fluid see chapter Technical Data for proper amount 9 Replace fill plug do not forget the seal ring 5 12 Conversion suction side top to suction side bottom The vacuum system needs to be changed for this purposes 1 Switch off the pump and secure it against restarting 2 Disconnect the pump from the pipeline system on suction and pressure side see chapte...

Page 40: ... 2000 Pressure Diameter rotor IP 600 IP 800 0 4 bar 543 mm 724 mm 4 6 bar 544 mm 726 mm 6 8 bar 547 mm 727 mm 8 10 bar 551 mm 728 mm 10 13 bar 552 mm 730 mm Version with rotor design from 2001 Pressure Diameter rotor IP 600 IP 800 0 2 bar 543 mm 722 mm 2 4 bar 543 mm 724 mm 4 6 bar 544 mm 725 mm 6 8 bar 547 mm 727 mm 8 10 bar 551 mm 728 mm 10 13 bar 552 mm 730 mm Version with rotor design up to 20...

Page 41: ...e pump can also be operated with a pumping hose without vacuum bore The installation procedure for a so called full fabric hose is identical with the procedure for a standard pumping hose Switch off the pump and secure it against restarting Then proceed as described in chapter 5 11 3 For troubleshooting see next page ...

Page 42: ...eliminate leaks of air Suction lift too high Check for vapour pressure change arrangement Motor incorrectly connected Check installation Low pump flow Discharge pressure too high Reduce pressure Leaks in suction pipe Find and eliminate leaks Speed too low Check speed and electric wiring Suction line blocked Remove blockage Viscosity too high Reduce viscosity or reselect pump Insufficient suction p...

Page 43: ...e Examine if necessary replace defective parts Air or gas in fluid Degas fluid Solids in fluid Install a dirt trap in the suction line Drive heats up or is A certain heating of electric Check the current overloaded motors is normal consumption to be sure Discharge pressure too high Reduce the pressure check the pressure gauge Fluid of higher viscosity than Install a stronger motor expected when de...

Page 44: ...Street P O Box 603 Piqua Ohio 45356 0603 USA Phone 937 773 2442 Fax 937 773 2238 www cranepumps com Email cranepumps cranepumps com A Crane Co Company PUMPS SYSTEMS Manual derived from ELRO BACD IP 18 GB 10 02 Be ...

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