VERDER PACKO ZL Series Operation & Maintenance Manual Download | Manualshive

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1.8 CONSTRUCTION

ZL series Rotary Lobe Pumps can be ordered with bare shaft, i.e. pumps without motor or base
plate.

Or, ordered as a complete unit with drive motor, coupling & guard, base plate (or trolley) and

layout described as below.

Example Layout of pumps with complete unit

①

Base plate,

②

Drive unit,

③

Coupling & coupling guard,

④

Gearbox,

⑤

Rotor case with inlet & outlet ports,

⑥

Front cover

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Summary of Contents for PACKO ZL Series

Page 1: ......

Page 2: ...lve 9 3 3 Connection of the motor 11 3 4 Connecting the mechanical seal flush 12 3 5 Start Up 12 4 CHECK THE PUMP ROTATION 4 1 Principle of operation 14 4 2 Direction of rotation 14 5 OPERATION 5 1 Troubleshooting 15 5 2 Cleaning 16 6 MAINTENANCE 6 1 Rotor Case Disassembly 17 6 2 Inspection 18 6 3 Seal Maintenance 19 6 4 Rotor Case Assembly 22 6 5 Rotor Clearance 23 6 6 Rotor Timing 24 6 7 Gearbox...

Page 3: ...3 COPYRIGHT These operating instructions are written to support the installation the use and the maintenance of the pump in accordance with the European machinery directive They are originally written in Dutch English French and German by the manufacturer All other languages are translations of the original operating instructions PACKO INOX LTD has the copyright on this document These operating in...

Page 4: ...ery and with the harmonised standard EN 809 ENISO12100 It must be brought to your attention that our product is intended to be built into a machine and that on the basis of the Machinery Directive the complete compound machine can only be applied after matching the stipulations of the European demands PACKO Inox Ltd Cardijnlaan 10 B 8600 DIKSMUIDE BELGIUM is authorized to make up the technical con...

Page 5: ... specified by the manufacturer The pump is only to be put into operation filled with medium to be pumped Before starting up ensure that Open the valves on the suction side completely to avoid cavitation and Open the valves on the discharge side completely to avoid exceeding the permitted differential pressure of the pump Discharge side safety measures should be done e g safety valve to protect the...

Page 6: ...ucer on trolley U pump and motor reducer on trolley with cover P bare pump Q pump and motor reducer aligned on base plate R pump and motor reducer aligned on base plate with cover Moreover the year and week of construction the pump serial number to be stated when ordering spare parts the weight maximum operating temperature and maximum differential head are also marked on the name plate 1 7 SOUND ...

Page 7: ...s without motor or base plate Or ordered as a complete unit with drive motor coupling guard base plate or trolley and layout described as below Example Layout of pumps with complete unit Base plate Drive unit Coupling coupling guard Gearbox Rotor case with inlet outlet ports Front cover ...

Page 8: ...ure you set the pump down on a stable horizontal surface Below a picture of the complete unit with drive base plate is shown as an example 1 10 STORAGE If the pumps need to be stored temporarily they should be preserved under normal environmental conditions and must not be exposed to the weather for any significant period of time Heed below measures when a longer storage period is required Protect...

Page 9: ...TING THE PUMP DO only qualified personnel should operate this pump DO NOT start the pump as long as someone is working on or touching the pump DO NOT touch the pump or the lines when pumping hot fluids or when performing Clean In Place CIP procedures DO NOT run the pump with BOTH the suction inlet or discharge outlet blocked Running the pump with the inlet or outlet blocked will cause serious dama...

Page 10: ...mperatures When a quench reservoir is applied the level of the flushing liquid in the quench reservoir must be guarded by an ATEX approved level sensor If the level becomes too high or too low the pump must be stopped The temperature in the quench reservoir should be guarded by an ATEX approved temperature sensor The temperature of the flushing liquid should be kept below 60 C If necessary an exte...

Page 11: ...ump which could lead to distortion 10 Ensure sufficient clearance around the motor and pump 11 The coupling alignment must be checked and readjusted if necessary 3 2 ADJUSTMENT PRESSURE RELIEF VALVE Instructions for the adjustment of the pressure relief valve for the PACKO rotary lobe pumps Pressure ratios of the individual pump types There are two types of pressure relief valves for each model hi...

Page 12: ...5 bar 58 mm 3 bar 57 mm 4 bar 52 mm 5 bar 48 mm 8 bar 45 mm 10 bar 43 mm 12 bar 20 bar high pressure 12 bar 51 mm 14 15 bar 50 mm 16 bar 49 5 mm 18 bar 49 mm 20 bar 48 mm ZL115 AND ZL120 0 bar 7 bar low pressure 2 bar 55 mm 2 5 bar 54mm 4 5 bar 50mm 6 bar 45 5 mm 8 bar 12 bar high pressure 7 5 bar 52 mm 8 bar 51 5 mm 10 bar 50mm 12 bar 48 5 mm ZL220 ZL225 0 bar 7 bar low pressure 3 5 bar 47 mm 7 b...

Page 13: ...er the motor can operate from the available voltage and frequency The connecting cables and the protection system against excessive currents must be chosen according to the data on the name plate of the motor The voltage drop during the starting of the motor may not exceed 3 Tighten the nuts of the connector terminals in accordance with the torque values Nm stated below Terminal M4 M5 M6 M8 M10 M1...

Page 14: ... the pump Never provide a valve or throttle in the flushing liquid outlet to prevent pressure build up in the flushing chamber Or connect the flush to a quench reservoir of at least 5 liters To ensure adequate circulation of the flushing liquid its viscosity must not exceed 100 centiPoise the hoses used must have an internal diameter of at least 14 millimeters and the hoses together must not be mo...

Page 15: ...maximum pressure as indicated on the nameplate of the pump The installation of a pressure relieve valve is recommended Pay attention to circumstances that could indicate pump cavitation 1 Low pressure in the suction line due to bad suction conditions 2 Air in the suction inlet line 3 Pumping temperature is too high 4 Pump is oversized ...

Page 16: ...the pump It is then transported in the space between the lobes and the periphery of the rotor case to the discharge side The volume between the rotors is reduced here and the product is forced out through the outlet 4 2 DIRECTION OF ROTATION The direction of flow is dictated by the direction of rotation of the drive shaft Reversing the direction of rotation will reverse the flow direction Top and ...

Page 17: ...sure high temp Leaks in piping or pump Dissolved gas in product Mechanical noise Excessive weight from piping Pump body distorted Excessive discharge pressure Worn bearing Worn gears Rotor to rotor contact Increase net inlet pressure Slow pump reduce product Reduce temperature Repair leaks Reduce discharge pressure Check tolerances Support piping Check align and level Reduce discharge pressure Rep...

Page 18: ...clean entire circuit For most applications a velocity of 1 5 m sec is sufficient For the CIP solution to achieve the proper velocity the pump drive must have enough speed range and horsepower The required inlet pressure also must be satisfied If the pump does not supply enough CIP solution velocity a separate CIP supply pump with an installed bypass may be used 4 Refer to the below CIP and SIP pro...

Page 19: ...cap nuts using the appropriate wrench During this process place all parts on a clean protected surface with finished surfaces and seal faces facing up If it is stuck tap the cover off using a soft mallet And then remove the cover O ring and inspect Remove rotor bolts using the special tool supplied with the pump or appropriate size wrench To remove rotor bolts place the plastic bar between rotors ...

Page 20: ...SPECTION While performing standard maintenance or cleaning check for signs of damage or extreme wear A simple inspection may show signs of a problem long before it becomes a serious issue Detection of such problems can avoid costly repairs and reduce down time 1 Inspect O rings and seals for re use Worn O rings and seals should be replaced 2 Inspect seal faces for chipping scratches or cracks Repl...

Page 21: ...ired you can easily dismantle and pull them out of the rotor case and rotors by only removing the rotors but without dismantling the rotor case thanks to the Front loading seal design Push the new seal rings into the rotor case and rotors The seal ring can be easily removed out of the rotor by using a small screw driver or pin as shown in Figure 11 This is common for the Single mechanical and Doub...

Page 22: ...inue Double Mechanical Seal Maintenance Remove the Seal ring from the rotor case rotor shown in Figure 16 and inspect them If any seal is damaged do not re use and replace it Clean both shaft ends and the rotor case before assembling Slide and insert the replacing NEW seal ring into the rotor case after Rotor Case Assembly chapter 6 4 After the rotor case has been removed Figure 5 pull out and rem...

Page 23: ...de insert the sleeves onto the shafts until they rest on the shaft shoulder Align the slot in the shaft sleeve to the drive pin on the shaft Place the rotor case face down on the table and loosen the wrench bolts and washers using appropriate wrench as shown in Figure 20 Pull the Lip seal out of the rotor case And insert the replacing NEW Lip seal making sure the holes in the seal to be lined up w...

Page 24: ...st rotor bolt with a special delivered tool to the below recommended torque Series ZL100 ZL200 ZL300 ZL400 ZL500 Bolt size M8 M14 M18 M18 M18 Torque Nm 17 35 48 56 56 To tighten the second rotor place the plastic bar on the opposite side of the rotor and tighten the second rotor bolt to the proper torque Be sure not to make any bur on the rotor bolt groove during this process It may cause a seriou...

Page 25: ...ntact has occurred during operation Within rated differential pressure check the rotor clearances and adjust if incorrect Standard Rotor Clearances mm Model Back Face Front Face Radial Sides Radial Top Bottom Rotor to Rotor ZL105 0 07 0 07 0 07 0 07 0 1 ZL110 0 07 0 07 0 07 0 07 0 1 ZL115 0 15 0 15 0 27 0 12 0 15 ZL120 0 15 0 15 0 3 0 13 0 13 ZL220 0 2 0 2 0 3 0 15 0 2 ZL225 0 2 0 2 0 4 0 2 0 2 ZL...

Page 26: ...aintained to provide maximum pumping efficiency and to prevent contact between rotors during operation If pumping efficiency is below expectations or if rotors contact during operation within rated differential pressure check rotor timing and adjust if incorrect Also check rotor timing after any gearbox dismantling when the gears are removed and or replaced Check Rotor timing as follows 1 Assemble...

Page 27: ... gear on the idle shaft using a depth micrometer shown in Figure 28 Adjust the gap using a spacer and shim s according to the below cases If the gear on the idle shaft is more forward than the gear on the drive shaft as shown in Figure 29 add a 6 mm spacer and shim s on the idle shaft to fill the gap If the gear on the driving shaft is more forward than the gear on the idle shaft as shown in Figur...

Page 28: ...f the oil seal is needed to be replaced Remove the paper gasket from the cover or Gearbox 3 Straighten the locking tab of the bearing lock washer Remove the lock nut 12 1 and lock nut washer 12 from the drive shaft 8 idle shaft 9 4 Pull the two helical gears 14 off from the drive shaft 8 idle shaft 9 5 Remove the gear keys 10 for both drive idle shafts 6 Remove the front bearing gland set bolts 23...

Page 29: ... face of the Gearbox 9 Remove the bearings and spacers 16 together from the shafts by pressing the shaft out of them Or remove bearings by puller shown in Figure 36 10 The taper roller bearings for ZL400 series must be kept together with in outside spacer and separate for drive idle shafts Fig 35 Fig 37 Fig 36 ...

Page 30: ...y There should be a tight sliding fit between the gearbox and the bearing outer rings Press the shaft into the gear case until bearings are fully seated 2 Lubricate and install the front bearing oil seals set into the bearing glands Place the front bearing gland set on both shafts Take care for the Oil seal spring inside of the gland set it should not be deflected during insertion Set the Bolt was...

Page 31: ...iming 6 Use a spanner wrench to tighten the gear lock nut on the drive shaft You can install the rotors to hold the shafts in place while you tighten the nut Tighten the locknut 12 on the idle shaft following the previous steps Lubricate and install the rear oil seal cover 11 onto the Gearbox 1 7 Install the paper gasket 26 to the gasket face of the Gearbox and mount the rear cover assembly over t...

Page 32: ...ons Check the oil level in the Gearbox weekly and top up the gear oil if necessary Filling quantities for each series are shown as follows Food Grade Gear Oil We recommend NEVASTANE XSH 150 to 460 or equivalent Synthetic PAO gear oils suitable for incidental food contact complying with below Qualifications Specifications The composition of the oils complies with the FDA chapter 21 CFR 178 3570 NSF...

Page 33: ... 8 440 12 450 8 Temperature Range depending on temperature class of the rotors max 120 C or max 150 C see nameplate For ATEX pumps the maximum temperature of the pumped liquid is 108 C Viscosity Range max 1 000 000cPs FLUSHED SHAFT SEALS Maximum Flushing Water Pressure Maximum 0 5 bar 7 psi Flushing Water Consumption 0 25 0 5 ℓ min 30 60 cubic inches min ...

Page 34: ...32 8 EXPLODED VIEWS 8 1 EXPLODED VIEW ZL100 ZL200 AND ZL300 EXPLODED VIEW ZL100 ZL200 AND ZL300 ...

Page 35: ...tain the following 1 Complete model number located on nameplate 2 Pump serial number located on nameplate 3 Description and position number from the exploded views SINGLE MECHANICAL SEAL TRIPLE LIP SEAL DOUBLE MECHANICAL SEAL Triple lip Seal ...

Page 36: ...34 O RING SEAL DOUBLE O RING SEAL FLUSHED MECHANICAL SEAL ...

Page 37: ...35 8 2 EXPLODED VIEW ZL400 ...

Page 38: ...36 SINGLE MECHANICAL SEAL TRIPLE LIP SEAL DOUBLE MECHANICAL SEAL Single Mech Seal Triple Lip Seal ...

Page 39: ...37 O RING SEAL DOUBLE O RING SEAL FLUSHED MECHANICAL SEAL O ring Seal Double O ring Seal ...

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