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Unibloc-Pump LABTOP 200, Operation And Service Manual

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Unibloc-Pump LABTOP 200 Operation And Service Manual Download Page 24

            

        Page 25 of 4

 

4.7 Troubleshooting  

 
 

PROBLEM POSSIBLE 

CAUSE 

SOLUTION 

A. 
No flow, but pump turns; pump does not 
prime 

1.           Motor turning in wrong                  
direction 
2. 

Air pocket in pipe or pump. 

 
3. 

NPSHA too low. 

 
 
 
4. 

Pump runs too slow. 

5. Viscosity 

too 

high. 

6. 

Obstruction in discharge piping, 

 valve 

closed. 

1. Reverse 

motor. 

2. 

Fill pipe and pump with liquid.  

 

Check pipe fittings for leaks. 

3. 

Increase suction pipe diameter 

or   
 

shorten suction pipe length. 

 

Decrease pump speed.  Raise 

               feed tank or supply liquid level.  
4. Increase 

speed. 

5. 

Lower viscosity if possible. 

6. 

Remove obstruction, open 

valve. 

B.  
Capacity too low, but pump turns 

1. 

NPSHA too low. 

2. 

Pump runs too slow. 

3. 

Increased slip in pump. 

 
4. 

Discharge pressure higher than 

 expected. 
 
 
 
 
 
5. 

Front cover not tight. 

 
6. 

O-ring installed in front cover is 

 too 

thick. 

1. See 

A-3 

2. Increase 

speed. 

3. 

Check rotor clearances; replace 

 

worn parts if necessary. 

4. 

Check discharge piping for 

 

closed valves or obstructions. 

               Increase pump speed BUT DO 
               NOT EXCEED PRESSURE 
               LIMITS OF PUMP. Increase  
               discharge pipe size. Increase   
                pump size. 
5. 

Tighten cover nuts to torques 

 

specified in section 5.3. 

6. 

Replace front cover o-ring with 

 correct 

size. 

 

C.  
Pump is noisy, cavitating 

1.           Collapsed suction hose. 
 
2. 

Liquid temperature too high. 

3. Speed 

too 

high. 

4. 

Viscosity higher than        

               Expectected 
5. 

NPSHA too low. 

6. 

Suction side valve closed 

 

1. 

Use reinforced hose or rigid    

               piping. 
2. Reduce 

speed, 

increase NPSHA. 

3. Decrease 

speed. 

4. 

Decrease speed, increase pump  

               size. 
5. See 

A-3. 

6. 

Open valve, check suction side 

 

piping for obstructions 

D.  
Rotors gall, pump seizes 

1. 

Liquid temperature too high. 

 
2. 

Rotor clearances incorrect. 

 
3. 

Loose rotor bolts/housing studs. 

4. Bearings 

worn. 

 

5. Gears 

worn. 

6. 

Foreign particles in pump. 

7. 

Particles in product too large. 

 
 
8. 

Discharge pressure too high. 

 
 
 
 
 

1. 

Lower temperature or increase 

               Rotor clearances. 
2. 

Adjust to factory recommended 

 clearances. 
3. 

Tighten or replace if necessary. 

4. Replace 

bearings. 

5. Replace 

gears. 

6. 

Install suction side filter. 

7. 

Increase rotor clearances. Use 

 

plastic rotors. Increase pump  

               size. 
8. See 

B-4. 

Summary of Contents for LABTOP 200

Page 1: ...OPERATION AND SERVICE MANUAL SERIES 200 450 ORIGINAL INSTRUCTIONS UNI 202204 ...

Page 2: ...ice 15 4 4 1 Single Mechanical Seal 16 4 4 1 1 UNIBLOC PD 200 275 Single Mechanical Seal Removal 16 4 4 1 2 UNIBLOC PD 200 275 Single Mechanical Seal Installation 16 4 4 1 3 UNIBLOC 3 300 450 Single Mechanical Seal Removal 17 4 4 1 4 UNIBLOC 3 300 450 Single Mechanical Seal Installation 17 4 4 2 Flushed Single Mechanical Seal 18 4 4 2 1 Flushed Single Mechanical Seal Removal 18 4 4 2 2 Flushed Sin...

Page 3: ...cs Operation 31 7 1 Input Voltage 31 7 2 Ventilation 31 7 3 Fuse Replacement 31 7 4 Unit Operation 32 7 4 1 Digital Key Pad Operation 33 7 4 2 Touch Screen Key Pad Operation 33 7 4 3 Controller Settings and Update 36 7 4 4 Remote Operation 36 8 0 Warranty 41 PLEASE REGISTER YOUR LABTOP TO RECEIVE UP TO DATE SOFTWARE FOR CONTROLLER REGISTRATION CAN BE DONE WITH ENCLOSED FORM OR FROM OUR WEBSITE WWW...

Page 4: ...sse 197 Beckum 59269 Germany Machine Description Rotary Lobe Pump Type UNIBLOC PD UNIBLOC GP Size PD200 677 GP200 450 Serial Number These machines have been designed and manufactured in accordance with the following transposed harmonized European Standards EN292 Parts 1 and 2 1991 Safety of Machinery Basic Concepts general principles for design EN294 1992 Safety distances to prevent danger zones b...

Page 5: ...lable in either Vertical or Horizontal Position The orientation can be modified using either a foot for horizontal or pedestal for vertical Port orientation should be specified when ordering Figure 1 0 Bearing housing Pump Model Bearing housing Pump Model Bearing housing Pump Model 200 Size 200 Size 200 Size 200 Size 200 0 200 250 275 300 Size 300 Size 300 350 400 Size 400 Size 400 450 Table 1 0 T...

Page 6: ...mps and or drives and or the systems within which they are installed can produce sound pressure levels that exceed 80dB In such cases ear protection should be used 1 2 3 Marking CE Figure 1 3 shows the tag that is attached on the pump bearing housing If the tag were to be lost for any reason you can find the pumps serial number machined on the side of the bearing housing See figure 1 4 Always stat...

Page 7: ...urpose Keep in mind that pipes filled with liquid are very heavy See figure 2 3 1 for recommended pipe layout Figure 2 3 1 Pump or pump assembly must be electrically connected by authorized personnel follow the motor instructions supplied in case of assembly Never operate the pump if the front cover and or suction discharge pipe work are not in place Make sure they are properly installed see figur...

Page 8: ... or relieved before dismantling Always ensure correct rotation of pump with flow direction before start Installation of safety equipment to prevent pump from exceeding maximum allowable pressure is recommended If an integrated safety relief valve is installed do not allow extended periods of recirculation through the valve UNIBLOC PUMP can either integrate a safety valve with the front cover or su...

Page 9: ...ease follow these steps Check packaging for any damage in transit Check the packing slip against received goods If an assembly make sure the manual for the drive unit is included Visually inspect the product for any signs of damage Report any damage immediately to the carrier If installation of the pump is delayed store and protect the unit properly by Not removing plastic port protectors Selectin...

Page 10: ...l or if the housing is jacketed for heating cooling Do not expose pump to rapid temperature changes this may seize the pump as a result from thermal shock Allow at least 1m 3feet free space around the pump for easy maintenance access Figure 3 2 1 shows a typical recommended design and required components for safe operation of the pump All components are available from UNIBLOC PUMP Contact your sup...

Page 11: ... pump is engaged and turned off after or at the same time the pump is disengaged VERTICAL PUMP PORTS recommended piping arrangement HORIZONTAL PUMP PORTS recommended piping arrangement FLUSH OUTLET PRESSURE GAUGE FLUSH OUTLET CONTROL VALVE i e diaphragm valve PRESSURE GAUGE FLUSH INLET CHECK VALVE SHUT OFF VALVE CONTROL VALVE i e diaphragm valve FLUSH INLET CHECK VALVE SHUT OFF VALVE Figure 3 3 1 ...

Page 12: ...mbers such that grease will be squeezed out of the seals along the shafts and into the rotor housing The amount of grease in the seal chambers must be monitored daily and if the pump is used in constant duty applications it should be checked several times every 24 hour period 3 4 Pre Start Check List Check the pipes to make sure they have been purged of debris Check all obstructions to make sure t...

Page 13: ...nditions Verify with UNIBLOC PUMP or the documentation supplied with the pump that the operating parameters are not exceeded Always rinse well with clean water after using cleaning agent 4 2 Steam In Place SIP The pump can be manually cleaned or cleaned with Steam In Place SIP Following is an example of suggested SIP procedure However specific advice for each application can be obtained from your ...

Page 14: ...y 1 1 wet end o ring kit Qty 1 5 o rings 4 4 Shaft Seal Service DISENGAGE POWER TO THE MOTOR before proceeding with the following steps If the pump is connected to piping depressurize the system and close valves on both the suction and discharge sides to isolate the pump from the rest of the system Disconnect the piping from the pump If service is to be performed while the pump is still mounted to...

Page 15: ...e Rotating Seal Faces the Rotating Seal O Rings and Rotating Seal Washers by sliding them off the shafts To avoid damage carefully handle and store the loose Stationary Seal Faces and the Rotating Seal Faces so that their lapped sealing surfaces do not get scratched 4 4 1 2 UNIBLOC PD 200 275 Single Mechanical Seal Installation If missing insert the Rotor Housing Pins into the rotor housing and th...

Page 16: ... Rotating Seal O Rings with water or coat them with a lubricant that is acceptable for use with the product Slide the Rotating Seal O Rings onto the shafts and then the Rotating Seal Faces slotted sides first Align the slots in the Rotating Seal Faces with the pins in the Drive Collars Push the Rotating Seal Faces against the Drive Collars so that the Rotating Seal O Rings seat properly Place the ...

Page 17: ...other seal parts have been removed back into the rotor housing seal bores Push or tap the lip seals with a tube to remove them 4 4 2 2 Flushed Single Mechanical Seal Installation Place the mating ring o rings 33a in the rotor housing seal bores Only lubricate these o rings with water or alcohol Push the mating rings into the rotor housing so that they seat flat with the step in the housing Do not ...

Page 18: ...e the rotor housing item 1 in Figure 4 4 1 by pulling on the ports or by tapping gently with a rubber mallet and lay it rotor cavity down so that the seals face up Do not rock the housing back and forth excessively or let it come in contact with the shaft splines The seals may break The entire Seal Package with the Flush Housings attached will come off with the rotor housing Unscrew the Bolts to r...

Page 19: ...onents on the Stationary Seal Faces primary Begin with Rotating Seal Faces primary slotted sides up Place the Rotating Seal O Rings primary into the Rotating Seal Faces primary Next place the Drive Collars into the the Rotating Seal Faces primary Making sure to align the slots with the pins push the Drive Collar gently to seat the o rings Place the Rotating Seal O Rings secondary on the Drive Coll...

Page 20: ...l slide the rotor shaft o rings 27 over the splined shaft ends and on the step if applicable One of the rotors will have a small marking on the rear end This indicates that this rotors match with the drive shaft Slide the rotors over the corresponding shafts and push them making sure the o rings seat properly The rotors must make contact with the shafts Place o rings 26 on the rotor bolts 14a 14b ...

Page 21: ...y removing the cover 7 Open the tab on the tabwashers 12 and remove them and the slotted nuts 13 With a rubber mallet strike the ends of the shafts where the tabwashers were located to loosen the gears 8 and remove them Be sure not to damage the threads on the shafts The keys 21 will now be exposed and can be removed with a flat tipped screwdriver Continue striking the shafts with the rubber malle...

Page 22: ... front bearing cups only to reveal the shim ring s Insert an appropriate shim and then repeat the steps described in this section If the clearances fall within the ranges specified then proceed to section 4 5 2 2 4 5 2 2 Pump Assembly Stainless Steel Rotors Final Step Lock the nuts in place by bending the tabwasher into the slots in the nut Install the front oil seals 23 by first lubricating with ...

Page 23: ... onto the drive shaft taking care not to damage the oil seal lips Secure the cover with the bolts 18 Tap key 22 into place Install the shaft seals and rotor housing as described in section 4 4 To service the valve seals the pump must not be operating the system must be depressurized and the pump isolated from the remainder of the system Remove the housing 10 and mark the location of the lock ring ...

Page 24: ...r obstructions Increasepump speed BUT DO NOT EXCEED PRESSURE LIMITS OF PUMP Increase discharge pipe size Increase pump size 5 Tighten cover nuts to torques specified in section 5 3 6 Replace front cover o ring with correct size C Pump is noisy cavitating 1 Collapsed suction hose 2 Liquid temperature too high 3 Speed too high 4 Viscosity higher than Expectected 5 NPSHA too low 6 Suction side valve ...

Page 25: ...salignment 1 Increase motor size 2 Lower pump speed Lower pressure Check suction and discharge piping for closed valves or obstructions 3 Decrease pump speed Increase pipe size or shorten discharge pipe length 4 Correct alignment G Shaft seals leak 1 Loose drive collar on single mechanical seals 2 Worn parts 3 Seals have been operated without product in pump or without flushing liquid 4 Seal incom...

Page 26: ...mains in its groove Tighten the cover bolts The pump is now ready to be installed in the system Refer to section 3 4 before starting the pump Non Permanent lubricated bearing housings Models 300 450 When checking the oil level in bearing housings that are not permanently lubricated the pump must first be stopped Remove the oil level check plug If oil does not come out of this hole it must be added...

Page 27: ... 152 250 305 Shell Spirax S 75W90 23 152 10 305 Sentinel S140 26 288 15 550 Royal Purple Poly Guard FDA 26 165 15 330 Table 5 2 1 UNIBLOC MODEL APPROX OIL CAPACITY ml oz 200 250 275 50 1 7 300 350 150 5 1 400 450 350 11 8 Table 5 2 2 ...

Page 28: ...ht Hand tight Rotating Rotate Turn Shaft by turning rotors bolt 14a Socket Size mm Torque Settings Nm Torque Setting lbft 10 with part 6006 2 2 1 5 13 4 3 17 6 4 5 Shaft Guard Canopy Bolts Key Size mm Torque Settings Nm Torque Setting lbft N A N A N A 4 Hand tight Hand tight 4 Hand tight Hand tight Oil Plug 47b Key Size mm Torque Settings Nm Torque Setting lbft N A N A N A 6 5 Hand tight Hand tigh...

Page 29: ...aring housing See detailed description under section 1 2 Each serial number is linked to a unique build code see example 1 0 below Example 1 0 UNIBLOC PD 5400 10 10 P20H 60 10T 12 E A B C D E Series Pump model Rotor cover type Rotor housing type Connection type and size Elastomer type Shaft seal type Shaft type Rotor type J H G F CLEARANCES FOR CLASS D STAINLESS STEEL ROTORS x0 01 mm x0 001in UNIB...

Page 30: ...ot contact Flowtech or your nearest service representative to verify the voltage of the unit DO NOT SWITCH THE VOLTAGE SELECTOR WITHOUT DETERMINING THE CORRECT VOLTAGE THE UNIT CAN BE DAMAGED Also make sure that the LABTOP s current draw will not exceed that allowed by the power source Fused circuit protection should be installed at the power source as well However the units will not function at a...

Page 31: ... display will illuminate and the unit is now ready to be operated or programmed All LABTOP units come preprogrammed and are ready for operation If you wish to operate the unit using a 4 20 mA input signal see Section 7 4 4 If the suction line to the pump is empty you may experience some difficulty getting the flow of liquid started This can be accomplished by increasing the speed until flow is est...

Page 32: ... key increases the speed up to a preset maximum DOWN In stop mode this causes the running speed to decrease in the display only The new speed may then be engaged by pressing FWD or REV In run mode pressing this key decreases the speed down to a preset minimum ENTER In stop or run modes pressing this key will store the selected frequency as the initial frequency when the unit is powered up The freq...

Page 33: ...crease in the display only The new speed may then be engaged by pressing FWD or REV In run mode pressing this key increases the speed up to a preset maximum DOWN ARROW In stop mode this causes the running speed to decrease in the display only The new speed may then be engaged by pressing FWD or REV In run mode pressing this key decreases the speed down to a preset minimum DISPLAY HZ Toggle to disp...

Page 34: ...ogram Settings screen see Figure 7 4 2 4 to view factory settings for unit RAMP SET UP Toggle to Ramp Settings screen see Figure 7 4 2 5 to change acceleration and deceleration ramp time Figure 7 4 2 3 Figure 7 4 2 4 Figure 7 4 2 5 ...

Page 35: ...updated software To update press hold SYS key in Figure 7 4 2 1 On numeric keypad type code 12345678 to enter System Screen in Figure 7 4 2 6 Insert USB into panel on side of canopy and press Run on keypad Software will automatically update and restart unit Once unit has restarted remove USB from side panel 7 4 4 Remote Operation The speed of the LABTOP unit may be changed from a remote location b...

Page 36: ...01 1 19 DRAIN PLUG 2 20 REAR OIL SEAL 4100 1 21 SHAFT KEY FOR DRIVE 4701 1 22 M8x25 HEX BOLT 4300 4 23 M6 DOME NUT 4400 4 24 ROTOR HOUSING COVER 3200 1 25 FRONT COVER O RING 2 987 x0 103 151 4200 1 26 ROTOR BOLT O RING 0 799 x0 103 117 4213 1 27 ROTOR BOLT 3352 2 28 ROTOR 2 29 ROTOR HOUSING STUD 4 30 ROTOR HOUISNG 1 BY SCALE APP D CHECKED DRAWN DATE ALL DIMENSIONS IN MM IN SHEET 1 OF 2 DWG NO 06 0...

Page 37: ...Page 38 of 41 UNIBLOC PUMP ...

Page 38: ... 22 BEARING HOUSING COVER 3560 3570 3580 1 23 HEX BOLT HBM6x16 HBM6x16 HBM10x25 4 24 DOME NUT DNM8 DNM10 DNM12 4 25 ROTOR HOUSING COVER 3210 3220 3230 1 26 O RING ROTOR HOUSING COVER 4210 4220 4230 1 27 O RING ROTOR BOLT 4212 4222 4232 2 28 ROTOR BOLT HEX HEAD SLOTTED 3360 3361 3370 3371 3380 3381 2 29 ROTOR 2 30 STUD ROTOR HOUSING FRONT SM8x20 SM10x25 SM12x30 4 31 ROTOR HOUSING 1 32 STUD ROTOR HO...

Page 39: ...Page 40 of 41 UNIB L OC PUMP ...

Page 40: ...omer by shipping it EX WORKS as defined in Incoterms 2020 the service facility Unibloc shall not be required to supply any labor for repairs or replacement of parts This warranty is void if the product has not been used as recommended or instructed has been altered or used with unauthorized accessories has been subject to misuse abuse or accident or has been damaged due to causes not related to po...

Page 41: ...2 Unibloc Hygienic Technologies LLC Patented Designs Shown Unibloc Hygienic Technologies LLC 1650 Airport Road NW Suite 110 Kennesaw Georgia 30144 USA Tel 770 218 8900 E Mail info unibloctech com www unibloctech com ...

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