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Voith IPC 4, Operating Instructions Manual

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41

Voith 

Turbo H + L

 Hydraulic GmbH & Co. KG

25000057510-TED-ENX-04

15 Maintenance

This section describes the maintenance of pumps.

Maintenance and repair work on the pump must only be carried out by authorized 
Voith personnel. To ensure trouble-free operation of the pump, make sure that the 
permitted operating conditions are maintained. In particular, ensure that the oil is 
clean and the permitted temperature range is adhered to.

The operator should create a maintenance plan for the entire system. 
The maintenance criteria and intervals are defined by the operator.

If a hydraulic system malfunctions during operation, there are various signs that  
indicate the hydraulic pump is starting to wear:
•  Increase in input power
•  Increase in pump operating noise 
•  Increase in cycle time / decrease in operating speed
•  Loss of pressure before reaching the consumer
•  Increase in the pressure fluid temperature difference between input and
 

output the pump with a fixed cooling water quantity

•  Increase in the difference between the pump housing temperature and operating
 

fluid inlet temperature

We recommend replacing the seals after a maximum operating time of 5 years.

Internal gear pumps 

Maintenance

www.Laheghi.com

Summary of Contents for IPC 4

Page 1: ...Internal Gear Pumps IPH IPC IPV S IPVP X IPVA IPN E IPM E Operating instructions 2016 04 01 www Laheghi com...

Page 2: ...H Co KG Schuckertstr 15 D 71277 Rutesheim 25000057510 TED DEX 04 April 2016 2016 Voith Turbo H L Hydraulic GmbH Co KG The original language is german This docu ment is a translated version This docume...

Page 3: ...3 1 Designated use 13 3 1 1 Areas of applications 13 3 1 2 Foreseeable misuse or improper handling 14 3 1 3 Other dangers 14 3 2 Personnel Qualification and obligations 15 3 3 Personnel Protective equ...

Page 4: ...al testing and commissioning 33 10 1 Checking the direction of rotation 33 10 2 Speed 33 10 2 1 Performance pump 33 10 2 2 Variable speed pump 33 10 3 Filling bleeding the pump 34 10 4 Bleeding the sy...

Page 5: ...oith internal gear pumps 45 17 2 Pump combinations 45 17 3 Torques 47 17 3 1 Calculating the torque of a hydraulic pump 47 17 3 2 Calculating the overall torque of a multi stage pump 47 17 3 3 Calcula...

Page 6: ...am of the pressure limiting valve 35 Fig 10 6 Temperature sensor 36 Fig 17 1 Examples of pump combinations 45 Fig 17 3 Calculating the torque for secondary shafts 48 Fig 17 5 Permitted torque on the m...

Page 7: ...d commissioning must Important notes only be carried out by trained personnel who have been briefed on the system The pumps must only be operated with the permitted data The hydraulic system must be d...

Page 8: ...g or the rating plate Attach the pump and ensure there are no axial or transverse forces acting on the drive coupling direc tion Remove the core plugs on the pump Prefill the pump with operating fluid...

Page 9: ...and the oil level is below the pump take special care during the bleed process The system is only bled when there are no jarring noises and there is no foam build up in the tank The pump can now be l...

Page 10: ...repair costs and downtime increase the reliability and service life of the pump In addition to the operating instructions you must observe the local laws ordinances guidelines and standards local regu...

Page 11: ...e IP by VOITH TURBO for use in explosive atmospheres e I II M2 2GD ck IIB T4 Extract from operating instructions relevant to explosion protection in respect of type IP explosion protected pumps Declar...

Page 12: ...about danger due to rotating parts Warning about danger due to suspended loads This warning symbol is placed before activities which can lead to multiple sources of danger This warning symbol is plac...

Page 13: ...d by following special warning notices in the technical docu mentation 3 1 1 Applications The internal gear pumps are designed and built solely in order to generate pressure fluid volume flow with a s...

Page 14: ...that affect the safety of pumps and the system Operating the pumps in non approved areas and overload conditions Neglecting the specified maintenance work and failing to observe the mainte nance and...

Page 15: ...ng to observe the operating and maintenance requirements improper operating materials Physical damage to other material assets in the operating range of the pumps can arise due to improper handling 3...

Page 16: ...only following consultation with the manufacturer making sure that the pumps are protected from unauthorized use ensuring the pumps are only operated when they are fully functional and safe for opera...

Page 17: ...facturer s operating instructions Do not make any alterations to tested approved and sealed safety and overpres sure valves Only run a fully functional and securely operating pump system Shut down the...

Page 18: ...th the manufacturer Use suitable tools for the maintenance work Expert maintenance or repairs can only be guaranteed by the manufacturer or authorized companies Unusable internal gear pumps should be...

Page 19: ...regulations and standards In this section you will find a list of the applicable directives regulations and standards 4 1 EU directives The following EU directives have been followed and should be tak...

Page 20: ...rection the axial plates seal the pressure chamber with the minimal possible gap This design minimizes volume losses and increases efficiency When the gears rotate the pinion teeth enter the gaps betw...

Page 21: ...ening the gear chambers The gear chambers are sealed in a radial direction by gear meshing and by the sealing lips and the pinion head This design minimizes volume losses and increases efficiency When...

Page 22: ...IN EN ISO 12922 2 No HFD No release Biodegradable Release by Voith Turbo H L Hydraulic is required in all cases Petroleum or similar fluids Release by Voith Turbo H L Hydraulic is required in all case...

Page 23: ...no HFC yes 3 1 0 8 50 75 100 30 60 1 Fig 6 2 Limitations 1 Warm up in depressurized state Before operating rinse the pumps with HFC fluid because mineral oil is used for preservation 2 IPME pumps can...

Page 24: ...ump combinations where the size or the volume quantity exceeds the cardboard boxes used are packed in crates For overseas shipments anti rust side gusseted bags are used in the cartons crates All seal...

Page 25: ...ift truck pallet jack etc Do not use loops to lift and transport the pumps Lift the internal gear pump as follows 1 Fit the steel ring screws DIN 580 with plastic shims 2 Screw the steel ring screws i...

Page 26: ...for transporting the pump A swinging pump could cause serious injury or death from squashing Ensure hands and feet do not become trapped when pumps are lowered Weights of up to approx 200 kg possible...

Page 27: ...ndividual pumps Thread sizes for screwing in the steel ring screws in accordance with DIN Avoid heavy knocks or impacts on the housing of the hanging pump as these could damage the axial gasket Drive...

Page 28: ...sion agents e g Tectyl 511 After 18 months of storage the pump must be checked by a trained expert or by Voith Turbo H L Hydraulic before installation aging process of the valve seals 8 2 Preservation...

Page 29: ...ot put under any strain as a result of pump misalignment there are no strains as a result of incorrectly assembled pipelines the coupling parts are assembled without excessive force for assembly of th...

Page 30: ...must be installed without voltage There must be no forces acting on the flange connections of the pump housing 9 2 2 Initial preparations The suction side large cross section and the pressure side sm...

Page 31: ...in accordance with the manufacturer s instructions 8 Lift the pump pump combination with the jack or equipment position on the pump carrier flange and push together 9 Turn the coupling on the pump in...

Page 32: ...n lead to malfunctions and damage the pump The sealant must not come into contact with the pressure fluid or the radial shaft sealing ring When using hydraulic pipes note the relevant DIN standards an...

Page 33: ...pressures For the permitted speed range see chapter 5 2 When operating pump combinations with different series or sizes note the permitted speeds of the individual pump stages The lowest speed value...

Page 34: ...pen will damage the pump 10 4 Bleeding the system The pump must be able to start up in a depressurized state i e without back pressure If any resistance for example a check valve with a charging press...

Page 35: ...Then load the pump with the projected pressure and secure the pressure limiting valve so that it cannot be adjusted The system is sufficiently bled when there are no jarring noises and there is no foa...

Page 36: ...with mounting screw lock washer and thermal grease and must be mounted At mounting please note the contact surface must be degreased and cleaned befo re wetting with the thermal compound The fastening...

Page 37: ...ht level difference changes between the oil level and pump the suction filter increased filter contamination the oil viscosity oil temperature changes the suction cross section if necessary the suctio...

Page 38: ...on of the pump during operation Please note that regardless of the direction of rotation the pressure must only ever be generated on the pressure side small cross section pressure is not allowed on th...

Page 39: ...is in progress DANGER Contact with live pipes can lead to serious injury and death Note the safety guidelines Before starting work Disconnect Secure against reactivation Ensure there is no voltage Gr...

Page 40: ...lf couplings 8 Remove the pump half coupling from the drive shaft 9 Loosen the screw connection between the pump carrier and the motor flange fully and remove the pump carrier housing 10 If necessary...

Page 41: ...maintenance criteria and intervals are defined by the operator If a hydraulic system malfunctions during operation there are various signs that indicate the hydraulic pump is starting to wear Increas...

Page 42: ...Suction piping above the permitted minimum operating fluid level Extend the suction piping The suction piping is not sealed Seal the pipe tighten the screw fitting The delivery pipe is blocked or prel...

Page 43: ...has sheared off Have the pump repaired by the manufacturer Damaged coupling Replace the coupling and install in accordance with the instructions The suction piping is unsealed Seal the pipe tighten th...

Page 44: ...gear pump technical data sheets 17 1 2 Key data The curves and technical data in the data sheets are valid under the conditions described If the pumps are used under other operating conditions such a...

Page 45: ...eflective surfaces piping etc are not taken into account Sound level measurements The sound pressure curves given were determined using series pumps in the Voith sound measuring room low noise room Co...

Page 46: ...essures Triple or quadruple pumps are possible On the attachment pumps secondary pumps to the main pump the drive shaft is always geared The individual drive shafts are connected via geared couplings...

Page 47: ...he total torque of the individual pump stages must not exceed the permitted values see chapter 17 4 Reduce pressure In view of this in the event of multistage pumps it may be necessary to reduce the g...

Page 48: ...tions show that the permitted values have been exceeded check whether the maximum possible pressures occur at the same time If simultaneous loads cannot be avoided there are two options reduce the pre...

Page 49: ...0 IPM E 6 605 400 Tab 17 4 Permitted input torques 17 5 Support for pump combinations Always install pump combinations strainless The pipe flange must be connected without pulling pushing or other str...

Page 50: ...5 240 200 108 IPC 6 420 350 140 IPC 7 900 IPH 4 120 100 75 IPH 5 420 350 140 IPH 6 1080 700 140 IPN 4 70 68 IPN 5 150 86 IPN 6 300 108 IPV S P A 3 25 20 IPV S P A 4 120 100 75 IPV S P A 5 240 200 108...

Page 51: ...ction piping If the suction cross section needs to be adjusted in the suction nozzle e g in the case of higher viscosity in order to achieve the permitted pressure this must be carried out immediately...

Page 52: ...rs oil viscosity suction cross section length of the suction pipe number and shape of direction changes in the suction pipe 17 7 Oil reservoir This section briefly describes the requirements for press...

Page 53: ...ion according to NAS 1638 class 8 according to ISO 4406 code 19 17 14 To ensure a longer service life we recommend filter according to 1638 class 7 or superior according to ISO 4406 Code 18 16 13 We r...

Page 54: ...DIN EN ISO 9001 Quality management for production Following a justified request the specific technical documents can be presented to the individual state bodies of the EU The documents are normally s...

Page 55: ...Voith Turbo H L Hydraulic GmbH Co KG Schuckertstra e 15 71277 Rutesheim Germany Tel 49 7152 992 3 Fax 49 7152 992 400 sales rut voith com www voith com hydraulic systems www Laheghi com...

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