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Vogelsang FX116, Operating Instructions Manual

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Vogelsang FX116 Operating Instructions Manual Download Page 39

Troubleshooting  

 

 

WBV.PU.003.EN FX116 V1.0 

39 

 

 

 

 

10  Troubleshooting 

 

 

WARNING 

Risk of injury (catching, crushing, collision) due to rotating rotary lobes if the machine starts up 
unexpectedly! 

Before starting maintenance and repair work (opening covers, disassembling connectors) and before 
troubleshooting, switch the machine off and secure it against being switched on again. 

 

 

10.1  Troubleshooting 

Troubleshooting 

Help 

 Chapter "Help"  

• 

No pump delivery 

A, B, D, G, J, O 

• 

Pump stops after start 

J, K, M, O, P, S 

• 

Intake flow breaks away after start 

D, E, G, S, S 

• 

Irregular pump delivery 

D, E, G, J 

• 

Capacity too low 

D, G, J, O, P, Q, R 

• 

Pump blocked 

C, F, J, K, M, O, R, S 

• 

Power consumption too high 

C, M, O, P, S 

• 

Drive belt slips 

F, H, M, O, P 

• 

Leakage at the pump 

C, O, R 

• 

Pump too hot 

A, C, M, N, O, P, R 

• 

Motor too hot 

C, K, L, M, O, P, S 

• 

Noises & vibrations 

C, D, E, F, G, I, J, K, M, N, O, P 

 

 

 

Personnel must wear appropriate protective clothing for the work listed in the following that may be 
necessary. 

 
 

10.2  Help 

 

Possible cause 

Possible measure 

Observe notes and 
safety notes 

 Chapter 

A 

Pump is not priming 

Fill the pump with fluid. 

 

B 

Incorrect direction of rotation 

Change the pump's direction of rotation. 

"Flow direction" 

C 

Pipe causing pump housing 
warping  

Check the orientation of the pipe to the pump. 
If necessary, provide a compensator or secure the 
pipe. 

"Installation in pipe lines" 

D 

Leakage in the suction pipe 

Check the suction-side pipe system for leakage. 

 

Gas formation 

Vent the suction pipe and pump chamber, fill with 
fluid. 

 

E 

Suction pipe clogged

  

Check the free flow of the pipe system on the 
suction side. 

 

F 

Foreign matter in medium 

Clean pump unit. Install strainer in the suction 
pipe. 

 

G 

NPSH

a

 too low (medium 

evaporates during feeding)

 

Increase the suction pipe diameter, shorten the 
suction pipe length, simplify suction pipe 
assembly, reduce the suction height, reduce the 
speed, adjust the medium temperature.  

"Installation in pipe lines" 

H 

Belt tension too low 

Tighten in accordance with manufacturer's 
specifications. 

"Installation of pump and 
motor on base" 

I 

Coupling not correctly 

Check the orientation and align according to 

Summary of Contents for FX116

Page 1: ...2016 01 18 WBV PU 003 EN FX116 V1 0 WBV PU 003 EN FX116 V1 0 1 45 2016 01 18 WBV PU 003 EN FX116 V1 0 WBV PU 003 EN FX116 V1 0 Operating Instructions Rotary Lobe Pump FX116 ...

Page 2: ... this document in any form is prohibited We reserve the right to make technical modifications to the diagrams and information presented in this document in the event that such modifications become necessary for the enhancement of the machine 2016 Hugo Vogelsang Maschinenbau GmbH Registered trademarks of Vogelsang Vogelsang RotaCut PreMix HiFlo ACC CFC BioCrack XTill EnergyJet and BioCut are regist...

Page 3: ... lobes 10 4 Safety 11 4 1 Operator s responsibilities 11 4 2 Personnel qualification 12 4 2 1 Qualifications 12 4 2 2 Fields of activity 12 4 3 Intended use 13 4 4 General safety notes 13 4 5 Warning and safety stickers on the machine 15 5 Transport storage 16 5 1 Transport 16 5 2 Storage 17 6 Assembly 18 6 1 Installation in pipe systems 18 6 2 Pipes 19 6 3 Direction of flow 21 6 3 1 Pump with mot...

Page 4: ... 3 Additional maintenance intervals for pumps with belt drive 43 13 Service plan 44 Table of figures Fig 1 Positions of the warning and safety labels 15 Fig 2 Transport aids 16 Fig 3 Installation variants 18 Fig 4 Long suction lines 20 Fig 5 Flow direction with motor drive 21 Fig 6 Flow direction with PTO drive 21 Fig 7 Flow direction with pump units 22 Fig 8 Tightening sequence 23 Fig 9 Orientati...

Page 5: ... of the machine Vogelsang does not accept any liability for damage resulting from failure to comply with these operating instructions KEEP FOR FUTURE REFERENCE Please keep the manual ready at hand to ensure easy access to the necessary information at all times Additional copies of the manual are available upon request 1 2 Presentation convention Presentation Meaning Listing Sublisting 1 2 Carry ou...

Page 6: ...s and information about environmental protection are marked by these symbols NOTE Refers to further information and useful notes ENVIRONMENTAL PROTECTION Refers to measures to be observed to prevent damage to the environment 3 Safety notes are introduced by these symbols and words CAUTION Refers to a dangerous situation in which failure to comply with the safety note could result in light injuries...

Page 7: ...lation the following optional machine versions are described Machine version Chapter reference With or without pump connectors Chapter Pump connector On a base or without a base Chapter Base support surface for machine With the following drive options Chapter Drive Electric drive Hydraulic drive PTO drive Combustion engine drive With or without system control Chapter System control The machines li...

Page 8: ... version marketed by us If a change is made to the machine without our agreement this declaration loses its validity Product Rotary lobe pump Applied harmonised standards DIN EN ISO 12100 2010 DIN EN 1037 1995 A1 2008 DIN EN 349 1993 A1 2008 DIN EN ISO 13857 2008 DIN EN 809 2012 Applied national standards and technical specifications DIN EN 82079 1 2012 DIN 4844 1 2012 DIN 4844 2 2012 DIN ISO 3864...

Page 9: ... capacity is lower it depends on the various operating conditions Valid only for short operation times For continuous operation please contact our service department The service time of the rotary lobes is reduced by high temperatures especially in combination with high differential pressure Free passage The maximum free passage is Ø 48 mm ATTENTION When using the pump for a highly viscous medium ...

Page 10: ...ive medium Highly wear resistant CSM CSM Hypalon Chloro sulfonyl polyethylene rubber 80 C Petrol oil acids alkali solutions Wear resistant acid resistant and alkali resistant FPM FPM Fluorocarbon gum 80 C Solvents salt water oil petrol acids Acid resistant and alkali resistant Steel lobes pure material 1 4571 150 C 200 C Pure medium Chemistry High temperatures high chemical resistance Steel rotary...

Page 11: ...a in which the machine is used must be complied with This includes the following in particular The operator shall ensure that all persons who handle the machine have read and understood this manual If necessary the operator shall train personnel and inform them of possible hazards To improve tracking we recommend creating a training log The operator shall clearly regulate and define responsibiliti...

Page 12: ... knowledge of the relevant provisions to perform the work for which he or she is responsible and is able to identify and avoid possible hazards independently Qualified electrician Is able due to his or her specialist training skills experience and knowledge of the relevant standards and provisions to perform work on electrical systems and is able to identify and avoid possible hazards independentl...

Page 13: ...sive atmospheres Any other use is contrary to the intended use Vogelsang is not liable for any damage resulting from such incorrect use 4 4 General safety notes WARNING Risk of injury catching crushing collision due to rotating rotary lobes if the machine starts up unexpectedly Before starting maintenance and repair work opening covers disassembling connectors and before troubleshooting switch the...

Page 14: ...mp housing the connectors or the pipes can become very hot At high speeds or high differential pressure the gearbox housing can also become very hot Avoid accidental contact with hot surfaces Avoid dry running of the pump e g by means of dry running protection via Temperature monitor Level measurement Flow measurement ATTENTION Risk of frost To protect the pump against damage caused by frozen medi...

Page 15: ... the stickers is for the safety of persons who work with and on the machine must remain legible remove any contamination if required may not be removed and must be replaced immediately if damaged or lost 1 VAU 133 Fig 1 Positions of the warning and safety labels example only the position of the stickers can vary depending on the size VAU 133 Before machine start up operating instructions must be r...

Page 16: ...ort storage 16 WBV PU 003 EN FX116 V1 0 5 Transport storage 5 1 Transport Pump without drive without base Pump with drive and connectors on base B Pump with drive and connectors on base C Fig 2 Transport aids ...

Page 17: ...he machine only for lifting and transporting the machine without attachments or system components e g motor connectors or base 5 2 Storage Long term storage of complete pumps individual O rings and seal components If not stored and handled properly the physical characteristics of products made of rubber may change Possible consequences include excessive hardening softening lasting deformation peel...

Page 18: ... be on the bottom and the outlet on the top If the pump is to be suspended please contact us When installing the pump ensure that there is easy access for maintenance work If the screw plugs for draining the gear oil are not easy to reach drain hoses may be used part no PBT 013 and or PBT 014 Ensure that the pump is tension free upon installation and also during operating upright horizontal suspen...

Page 19: ...ng system is optionally available from us setting at 10 over the nominal pressure of the pipe WARNING Risk of injury from medium escaping under high pressure If the maximum pressure is exceeded Chapter Specifications parts may burst and the pumped medium may be expelled under high pressure Follow the recommendations for pipes Only use high pressure pipes on the discharge side Up to nominal diamete...

Page 20: ...Suction lines whose diameter is too small may restrict the suction capability of the pump Caution risk of cavitation If the diameter of the suction pipe is too small the maximum suction height will be reduced by the loss of pressure due to pipe friction Contact us for a calculation Suction lines over 30 m must be laid with a slope of at least 2 x pipe diameter in the direction of flow ensuring tha...

Page 21: ...Pump units 6 3 1 Pump with motor drive If you are using motor driven pumps with one drive shaft the flow direction is selected by determining the direction of rotation of the drive motor such as an electric motor or hydraulic motor Fig 5 Flow direction with motor drive 6 3 2 Pump with PTO drive If you are using tractor driven pumps with two drive shafts connect either the upper or lower cardan sha...

Page 22: ...ersal of the flow direction is not possible if the pipelines are protected by automatic check valves WARNING Risk of injury from medium escaping under high pressure If a connector has a sight glass the sight glass may burst if the pressure is too high A connector with a sight glass must be installed on the suction side The pressure may not exceed max 2 bar during reverse pumping A Sight glass Fig ...

Page 23: ...tors Fig 8 Tightening sequence Tightening torques M 8 hexagon head bolt 8 8 steel 25 Nm M 8 hexagon head bolt A2 stainless steel 20 Nm Re tighten all bolts for fastening the connections after 20 operating hours and then every 2000 operating hours at least once a year ATTENTION Before installing stainless steel bolts and stainless steel nuts Clean threads and contact surfaces Apply anti seize paste...

Page 24: ...s and discomfort Install the base in a stressless manner on the support surface Retighten all screws and nuts for fastening the motor and the machine to the base after 20 operating hours and then every 2000 operating hours at least once a year After fastening the machine to the base and the base to the ground on which the machine is standing the coupling orientation must be checked and realigned i...

Page 25: ...ing must be complied with To protect the machine against damage caused by vibrations check the orientation of the coupling before start up and then every 2000 operating hours at least once a year and correct it as necessary Fig Orientation procedure If alignment errors are determined or after any blockage e g by foreign matter check the function of all parts of the drive line and readjust it if ne...

Page 26: ...ive For this type of construction please request the document Technical information TINF PU 020 xx accompanying sheet for belt drives For machines with belt drive check the belt tension acc to the accompanying sheet Chap Maintenance plan At start up Before and after long periods of shutdown After the first 10 operating hours Every 2000 operating hours once per year minimum 6 5 6 Machine on hand ca...

Page 27: ...ing installation in the pipe RISK OF ELECTRIC SHOCK Touching live parts leads to dangerous electrocution This can result in electric shock burns or death RISK OF ELECTRIC SHOCK The equipotential bonding shall be executed in accordance with standard EN 60204 1 In other words all metallic parts of the machine or plant must be connected electroconductively to each other or to the signal ground 39 mod...

Page 28: ...s read and follow the manufacturer s specifications for hydraulic motors Observe the permissible hydraulic pressure and the permissible delivery rate Connect the overflow oil line in accordance with the manufacturer s instructions Replace hydraulic hose lines that show signs of damage or ageing Only use genuine Vogelsang hydraulic hose lines The date of manufacture of the hydraulic hose line is di...

Page 29: ...n hot motor parts and cause serious burns Only refuel when the engine is switched off Never refuel in the vicinity of open flames or ignitable sparks Do not smoke Do not spill fuel WARNING Risk of burning due to exposed host surfaces Parts of the exhaust system and the surface of the engine become hot during operation and must not be touched until they cool down again once the engine has been swit...

Page 30: ...ating shaft end Before start up operation make sure that a suitable PTO shaft guard is installed If no suitable PTO shaft guard is present please request one from us Operating torque limitation for PTO drive In order to prevent overloading the pump drive shaft the operating torque must be limited With cardan shafts with a profile Operating torque limited to 1 3 8 6 part 1600 Nm 1 3 4 6 part 3200 N...

Page 31: ...used in variable frequency drive operation Advantages Adaptation to operating conditions viscosity delivery rate NPSHavail Wear compensation Speed proportional delivery rate see characteristic line Increasing acceleration and deceleration times Reduces pressure peaks Reduces the risk of pipe vibrations A variable frequency drive with a linear torque characteristic line is to be used The starting t...

Page 32: ...anying sheet for belt drives Is the motor connected correctly to the power supply if applicable documents provided by the motor manufacturer Star or delta connection voltage frequency see name plate and inside of terminal box Motor protection ensured e g by a circuit breaker A short switching time should be set for star delta starting if present A short start ramp should be set for the soft starte...

Page 33: ...s or maintenance switches easy to reach Put the pump into operation and check inlet and outlet pressure speed and capacity 7 2 Checks after start up 20 hours after start up perform the maintenance intervals in Chap Maintenance plan This includes checking the tightening torque of the hexagon head bolt Tightening torque M 12 hexagon head bolt 12 9 140 Nm ...

Page 34: ...inst being switched on again WARNING Skin and eye irritation caused by contact with hazardous working materials or media All work on the machine can lead to contact with working materials or media Personnel must wear suitable protective clothing The operator must inform his or her staff about any potentially hazardous substances in working materials or media To protect against fluids spraying out ...

Page 35: ...ew plug If no oil is touching the magnets top up small quantities Inspection interval Every 500 operating hours however at least every 3 months Change gear oil After the first 20 operating hours Every 2000 operating hours Upright installation Horizontal installation Fig 11 Gear oil change 1 Hexagon head screw plug A Fill 2 Magnetic hexagon head screw plug B Drain C1 Check The hexagon head screw pl...

Page 36: ...int 42 C DIN ISO 3016 Damage loading step 12 Water hazard class Slightly hazardous to waters When using BSS0021 oil for the pump gearbox the maintenance interval for checking and changing the gear oil may be doubled Chapter Maintenance plan Part number BSS 010 Description Medical white oil water white non fluorescent tasteless and odourless mixture of hydrocarbons Trade name Fuchs White oil W 530 ...

Page 37: ...aused by contact with hazardous working materials or media All work on the machine can lead to contact with working materials or media Personnel must wear suitable protective clothing The operator must inform his or her staff about any potentially hazardous substances in working materials or media 9 1 Conversion and spare parts Modifications or changes to the machine are only permissible after con...

Page 38: ...ssembling the gears check the tightening torque of the hexagon head bolt Tightening torque M 12 hexagon head bolt 12 9 140 Nm 9 3 Installation of extracting rings Make sure to install the spacer washers correctly Series Spacer washer Part no Installation position FX116 Without groove PRS0339 Drive end at the fixed bearing With groove PRS0340 At gearbox side at the floating bearing 9 4 Rotary lobe ...

Page 39: ...2 Help Possible cause Possible measure Observe notes and safety notes Chapter A Pump is not priming Fill the pump with fluid B Incorrect direction of rotation Change the pump s direction of rotation Flow direction C Pipe causing pump housing warping Check the orientation of the pipe to the pump If necessary provide a compensator or secure the pipe Installation in pipe lines D Leakage in the suctio...

Page 40: ...edium resistance of the lobe elastomer Material description for rotary lobes Stiff running caused by accumulation of solid matter in the gaps Clean pump chamber adjust drive Repair Connection to the power supply N Oil level in the gearbox is not OK Chapter Gearbox Maintenance O Differential pressure too high Reduce differential pressure Specifications P Medium viscosity above the nominal value Red...

Page 41: ...y Personnel must wear suitable protective clothing Take care when undoing bolts and screws 3 Drain working materials Drain the gear oil from the pump gearbox Observe notices and safety notes Chap Maintenance Chap Gear oil inspection and change 4 Drain the pump and remove residual medium Observe notes and safety notes when opening the bearing housing cover Chap Repair Chap Lobe change Environmental...

Page 42: ...e changes or if vibrations occur Chap Help in the event of application problems 12 2 Maintenance intervals ATTENTION Carefully follow the following maintenance intervals and those documented in the service plan Chap Service plan Before start up Check pump motor coupling orientation base C After the first 20 operating hours Retighten the screws for fastening the pump connectors Retighten the screws...

Page 43: ... fixed screw connection of coupling guard base C Check pump motor coupling orientation base C Change gear oil 12 3 Additional maintenance intervals for pumps with belt drive See also Technical information for belt drives TINF PU 020 xx Before start up and after long periods of shutdown Check belt tension and belt orientation After 0 5 to 4 operating hours Check belt tension Every 6 months Check be...

Page 44: ...he screws for the pump connectors Retighten the screws for the base or machine attachment Check fixed screw connection of coupling guard base C Check pump motor coupling orientation base C Check the tightening torque Check gear oil Change gear oil On pumps with belt drive Others maintenance instructions Operating hour meter Total capacity Date Name Sign ature Check belt tension Check belt orientat...

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