Wright Flow Technologies Revolution R0150X Installation, Operation And Maintenance Manual Download Page 1

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Installation, Operation

and

Maintenance Manual

for the

Frame 6 & 7

Summary of Contents for Revolution R0150X

Page 1: ...Installation Operation and Maintenance Manual for the Frame 6 7 ...

Page 2: ... 1 Revolution Pumping Principal 12 3 2 Revolution Pump Head Modularity 12 3 3 Revolution Range Operating Parameters 13 3 4 System Design 15 3 4 1 System Design and Installation 15 3 4 2 Installations with CIP Systems 18 3 5 Start Up Procedure 18 3 6 Shutdown Procedure 19 3 7 Routine Maintenance 20 3 8 1 Flushing Positions Size 7 21 3 8 2 Flushing Positions Size 6 22 3 8 3 Recommended Flush Circula...

Page 3: ...mits 52 6 0 Specifications 54 6 1 Clearance Chart 54 6 2 Fasteners Torque Settings 56 6 3 Lubricants 58 6 4 Material Specifications and Pump Weights 60 6 5 Pump Lifting 61 6 6 Foundation Dimensions 62 6 7 Trouble Shooting 64 6 8 Typical Noise Emission Data 65 Reference Only 65 Values taken during testing at random viscosities and pressures 65 Note values given can vary greatly depending on applica...

Page 4: ...pump was originally supplied without confirming its suitability for the new duty Running of the pump outside of its operation envelope can cause mechanical contact excessive heat and can represent a serious risk to health and safety Installation and operation of the pump must always comply with health and safety regulations A device must be incorporated into the pump system or drive to prevent the...

Page 5: ...sure that all piping connecting to the pump is fully supported and correctly aligned with its relevant connections Misalignment and or excess loads will cause severe pump damage This could result in unexpected mechanical contact in the pump head and has the potential to be an ignition source Be sure that pump rotation is correct for the desired direction of flow refer to section 3 5 Do not install...

Page 6: ...g 85 dB A under certain operating conditions When necessary personal protection against noise must be taken Avoid any contact with hot parts of pumps and or drives that may cause injury Certain operating conditions temperature control devices jackets heat tracing etc bad installation or poor maintenance can all promote high temperatures on pumps and or drives When cleaning either manually or by CI...

Page 7: ... contact Leakage Build up of explosive gas Rare Selection of seal system must be suitable for application See Chapter 5 0 Service plan Seals must never run dry Auxiliary system for shaft sealing Pump liquid leakage Build up of explosive gas Rare Selection of auxiliary seal system must be suitable for application Seals must never run dry Rotation direction test Excess temperature Very Rare If flush...

Page 8: ...rk upon the carriers paperwork that the goods have been received in a damaged condition with a brief description of damage If the pump is not required for immediate installation then it should be stored in a clean dry environment It is recommended that storage temperature should be between 10 and 40 C 14 F and 105 F 2 4 Cleaning The Revolution pump series is suitable for both manual cleaning and C...

Page 9: ...roviding the pump model and serial number as stated on the pump nameplate see Fig 2 which is fixed to the pump gearbox Should this be damaged or missing the pump serial number is also stamped on opposite corners of the rotorcase see Fig 3 Fig 2 Nameplate Fig 3 CPP Circumferential Piston Pump RLP Rotary lobe Pump R Revolution X Setup for CPP and RLP P Setup for CPP L Setup for RLP R 0300 PUMP RANGE...

Page 10: ...el of protection when endangered by an explosive atmosphere for equipment providing a high level of protection when likely to be endangered by an explosive atmosphere for equipment providing a very high level of protection when used in areas where an explosive atmosphere is very likely to occur for equipment providing a high level of protection when used in areas where an explosive atmosphere is l...

Page 11: ...Page 11 Standard Pump Component Terms Fig 4 SHAFTS TIMING GEAR BEARINGS FRONT COVER ROTOR RETAINER ROTOR ROTORCASE FOOT GEARBOX GEARBOX COVER DOME NUTS ...

Page 12: ...he suction port see Fig 5 the cavity generated increases creating a pressure decrease which induces the pumped medium to flow into the rotorcase The pumped medium is carried around the rotorcase by the rotors to the discharge side of the pump here the cavity decreases and the pumped medium is discharged from the rotorcase For pump component terms see Fig 4 Fig 5 3 2Revolution Pump Head Modularity ...

Page 13: ...ANDARD CLEARANCES FOR 93 C 200 F b FRONT FACE CLEARANCE 105 C 220 F c HOT CLEARANCES FOR 150 C 300 F d CHOCOLATE CLEARANCE e CLEARANCES FOR 93 C 200 F STAINLESS f FRONT FACE CLEARANCE 105 C 225 F STAINLESS g HOT CLEARANCES FOR 150 C 300 F STAINLESS h CHOCOLATE CLEARANCE STAINLESS The pump should not be subjected to sudden temperature changes to avoid the risk of damage from sudden expansion contra...

Page 14: ...5 600 21 92 CPP R0800X 3 0 8 0 2 17 247 600 28 122 RLP R0800X 2 5 0 8 0 2 9 131 800 39 173 CPP R1300X 3 1 0 3 14 203 600 36 159 RLP R1300X 3 1 1 0 3 7 102 800 51 226 CPP R1800X 3 1 5 0 4 31 450 600 53 231 CPP R1830X 3 1 5 0 4 31 450 600 53 231 RLP R1800X 3 1 6 0 4 15 218 600 56 246 CPP R2200X 4 2 0 5 21 305 600 71 313 CPP R2230X 4 2 0 5 21 305 600 71 313 RLP R2200X 4 2 1 0 6 8 116 600 76 333 CPP R...

Page 15: ... the pump suction and discharge connections to allow the pump to be isolated from the system for routine inspection and maintenance Circumferential piston and rotary lobe pumps are of the positive displacement type and therefore an overload protection device must be provided This can take the form of An in line pressure relief system i e external to the pump Incorporation of a torque limiting devi...

Page 16: ...imum number of bends tees and pipe work restrictions are used Calculations to determine system NPSHa are carried out for the worst condition see below Should advice on pump or system NPSH characteristics be required contact the factory or their authorised distributor Fig 7 10 0 Meters 32 8 Feet Water Column Suction Lift Or Vacuum Atmospheric Pressure Suction Head NPSH Available Suction Line Fricti...

Page 17: ...rsonal injury Guards should be of suitable material see d and of sufficiently rigid design to prevent contact with rotating parts under normal operating conditions d When the pump is installed in a flammable or explosive environment or is used for handling flammable or explosive materials special consideration must be given Not only to the safety aspects of the drive unit enclosure but also to the...

Page 18: ... flushed product seals check all auxiliary services are in place and connected and provide sufficient flow and pressure for flushing purposes Ensure lubrication is provided for both pump and drive The Revolution can be shipped with different lubrications see section 6 3 for capacities and grades If an external relief valve is incorporated in the system check that it is set correctly For start up p...

Page 19: ...visual check on suction and discharge pressure gauges and monitor the pump temperature and absorbed power where possible 3 6Shutdown Procedure When shutting the pump down stop pump close both the suction and discharge valves and ensure that the necessary safety precautions are taken The prime mover power source has been isolated If installed pneumatically operated integral relief valve has been de...

Page 20: ...r 3000 operating hours whichever is the sooner For lubricant capacities and grades refer to section 6 3 3 8Double Seal Flushing Locations Flush fluid should always fill seal chamber from the bottom port and exit out the upper most port In and out are dependent on orientation of pump WARNING ...

Page 21: ...Page 21 3 8 1 Flushing Positions Size 7 A B C D E F Connection MM Inch MM Inch MM Inch Degrees MM Inch MM Inch Size 7 170 6 69 513 20 20 174 2 6 86 50 136 89 5 39 160 6 3 1 4 BSP B A F E C D ...

Page 22: ...Page 22 3 8 2 Flushing Positions Size 6 A B C Connection MM Inch MM Inch MM Inch Size 6 CL CL 188 76 7 43 101 3 3 99 1 8 BSP C B A CL of Mounting Hole ...

Page 23: ...t Flush Horizontal Circular Flush Note The liquid supply connections to flushed seals are made using the threaded ports on the sides of the rotorcase The pipe work should be arranged to provide an independent flush to each seal Flush In or Flush In or Out Flush In or Out Flush Out or ...

Page 24: ... liquid supply connections to flushed seals are made using the threaded ports on the sides of the rotorcase The pipe work should be arranged to provide an independent flush to each seal Vertical Straight Flush Vertical Circular Flush Flush In Flush In Flush Out Flush Out Flush In Flush Out ...

Page 25: ...ly connections to flushed seals are made using the threaded ports on the sides of the rotorcase The pipe work should be arranged to provide an independent flush to each seal Flush In Flush In Flush Out Flush Out Flush Out Flush In ...

Page 26: ...ion Lip seals and o rings are incorporated within the gearbox assembly to contain the lubricant for the bearings and timing gears Regular inspection and correct maintenance of these items will ensure that the lubrication is sustained and the pump maximum working life is achieved To ensure this it is extremely important that care is taken when removing and replacing new o rings and lip seals When r...

Page 27: ...ilable from the factory to assist in lip seal installation of Frame 7 gearbox cover Figure 9 Frame 7 Lip Seal Installation Tool All fasteners are required to be tightened to the required torque setting during assembly refer to section 6 2 WARNING ...

Page 28: ...15 1 Remove the front cover dome nuts Remove the front cover and the front cover o ring Remove the rotors by unscrewing the rotor retaining bolts and o rings remove 3 bolts and rotor retainer plates and o rings taking care not to damage the product seal components ...

Page 29: ...Page 29 4 1 2 Rotorcase Removal Fig 16 Remove the 2 Seal Housings making sure that the static face is not damaged Remove the 2 rotorcase retaining screws and then remove the rotorcase Remove the guard ...

Page 30: ...Page 30 4 1 3 Gearbox Disassembly Fig 17 Make sure the gearbox lubricant has drained by removing the drain plug Remove the drive key Remove the hexagon head bolts and remove the gearbox cover ...

Page 31: ... used to aid gear removal with a puller tool The 2 threaded holes are to be used only in conjunction with gear pullers any other use will damage components Remove the gear keys and then remove the gear spacer Keep the locknut tab washer gear key shims and gear spacer in the sets that they were removed and identify them drive and lay ...

Page 32: ...p these in the sets that they were removed and identify them drive and lay Remove the screws holding the lip seal carriers Remove the optional gamma seal counter face gamma seal bearing retainer plate and the o ring At this point the shafts are not held in place so take care when moving the gearbox ...

Page 33: ...Page 33 4 1 6 Shaft and Bearing Removal Fig 20 Using a light press remove the shafts Fig 21 Remove the bearings and spacer using a press ...

Page 34: ...tion protective gloves should be used Once bearing cones are installed in the correct position they should be allowed to cool before proceeding with assembly After bearings cool they need to be pressed to assure they are fully seated Press to 15 tons make sure necessary procedures are used to prevent component damage During assembly press taper bearings onto shaft then press roller bearing onto sh...

Page 35: ...foot screws need to be retained using a thread locking compound adhesive Loctite 270 or similar Press in the rear outer shells of the needle roller bearings Press in the dowel bushes The dowel bushes need to be retained using a retaining compound adhesive Loctite 638 or similar ...

Page 36: ... against the outer bearing race with an appropriate tool to fully seat the bearing and shaft assembly Bench or holding apparatus must be of sufficient strength to hold weight of pump while tapping shaft into place When installing the shafts make sure they are installed square to the gearbox and that none of the rollers on the needle roller bearing get obstructed Install the lip seals into the bear...

Page 37: ...ark should correspond with the drive shaft The drive gear must be installed onto the drive shaft The drive gear can be identified by looking at the direction of the helix angle if the helix angle is slanting to the right then it s the drive gear see below When installing the gears note the gear spacer and the keys must be installed first otherwise the gear will foul on the gearbox and the timing w...

Page 38: ...drain plugs Install the lip seal into the gearbox plate Seal the gearbox plate using flange sealant dow corning 732 or similar and secure using the screws See section 6 2 for torque settings Install the drive key Install the rotorcase studs The rotorcase studs need to be retained using a thread locking compound adhesive Loctite 270 or similar Install the anti rotation washers and secure them with ...

Page 39: ...ge 39 Install the dowels The dowel bushes need to be retained using a retaining compound adhesive Loctite 638 or similar Install the guard and rotorcase and secure using the retaining screws Fig 35 Fig 34 ...

Page 40: ...6 1 to see how much shim you need to add remove from the shimming point After the front clearances have been set install the o ring into the setting ring When checking the front and rear clearances secure the rotorcase in place using washers and nuts on the studs protruding from the gearbox After the front clearance has been set check the radial clearances See section 8 1 for clearance settings Sh...

Page 41: ... head cap screws set the torque See section 6 2 Install the rotor retainer cap o ring and the rotor retainer cap Install the rotor retainer o ring and retainer set the torque See section 6 2 The rotorcase studs need to be retained using a thread locking compound adhesive Loctite 270 or similar Install the front cover o ring front cover and secure with the dome nuts ...

Page 42: ...Page 42 5 0Seal Section 5 1Single Seal Fig 39 1 Frame 6 Single Seal Cross Section Fig 39 2 Frame 7 Single Seal Cross Section ...

Page 43: ...8mm of the Frame 6 pin should stand out and 12 5 mm of the Frame 7 pin should stand out Install the o ring into the rotor Install the rotary face into the rotor making sure the pins line up with seal face slots Install clips onto pins Rotor Rotary Face E Clip O Ring Pin ...

Page 44: ...ousing o Install the seal housing into the rotorcase o Install o ring over seal face o Install wave spring into housing o Install static seal face o Install C Clip o Alternatively put seal together on bench and install as unit Seal Housing C Clip O Ring Wave Spring O Ring O Ring Static Seal Face ...

Page 45: ...p o Alternatively put seal together on bench and install as an assembly Frame 6 and 7 Special Seal Installation Tool o Although not necessary but advised use seal installation tool part number RA69 4000 01 for Frame 6 and RA79 4000 01 for Frame 7 available from factory to assist in installation Align seal housing to anti rotation washer retainer washer Slightly push seal into rotorcase to engage h...

Page 46: ...Page 46 Do not damage or chip seal face if seal face chips replace seal Install rotor retainer bolts through seal installation tool Tighten bolts to draw seal tight into rotorcase Fig 41 3 WARNING ...

Page 47: ...Page 47 5 2 Double Seal Flushed Fig 42 1 Frame 6 Double Seal Cross Section Fig 42 2 Frame 7 Double Seal Cross Section Fig 43 1 Frame 6 7 Rotary Seal Face ...

Page 48: ...e 7 pin should stand out Install the o ring into the rotor Install the rotary face into the rotor making sure the pins line up with seal face slots Install clips onto pins Install oring into secondary face Install secondary face over shaft Rotor Rotary Face O Ring E Clip Secondary Face O Ring Pin ...

Page 49: ... with anti rotation washer on the rear of the rotorcase o Install secondary wave spring o Install oring over secondary seal face o Install secondary seal into housing using C clip o Install primary wave spring o Install o ring over primary seal face o Install primary seal into housing using C clip O Ring O Ring Seal Housing Primary Static Seal Secondary Static Seal Primary Wave Spring Primary C Cl...

Page 50: ...stall oring over secondary seal face o Install secondary seal into housing using C clip o Install o ring over primary seal face o Install primary seal into housing using C clip Frame 6 and 7 Special Seal Installation Tool o Although not necessary but advised use seal installation tool part number RA69 4000 01 for Frame 6 and RA79 4000 01 for Frame 7 available from factory to assist in installation...

Page 51: ... tool Tighten bolts to draw seal tight into rotorcase Fig 44 3 5 3 Flushed Product Seals Auxiliary Services i Terminology Flush To provide a liquid barrier that is induced to flow through the seal area by an external means ii Flush Media The media used for flushing a seal area must be fully compatible with the pumped media and the relevant materials of construction of the pump Special consideratio...

Page 52: ... rate of the barrier fluid should be calculated to achieve the required amount of heat removal per formula above As a guide 2 to 3 litres min for Carbon v St St Carbon v SIC 3 to 4 litres min for SiC v SiC TC v SiC The barrier fluid should be clean and stable Do not operate seal in product temperatures in excess of 248 F without consulting Wright Flow applications engineering The flush media must ...

Page 53: ...seal Max pressure at speed Max speed at pressure Carbon v Silicon Carbide 1 bar 14 5 psi 400 rpm 400 rpm 1 bar 14 5 psi DIRECTION OF ROTATION The Revolution series mechanical seals are independent of the direction of rotation TEMPERATURE LIMITS Following temperature limits apply to the different seal faces commonly used within mechanical seals Seal face max operating temperature dependent on liqui...

Page 54: ...Page 54 Rear Front 6 0 Specifications 6 1 Clearance Chart Radial Radial Hub Hub ...

Page 55: ...Page 55 Revolution CPP 808 ALLOY ...

Page 56: ...Front Cover Qty Pump 4 4 Rotorcase Size mm M20 M24 Torque Nm 160 320 Torque ft lb 120 236 Button Head Cap Screw Anti Rotation Washer Qty Pump 2 2 Rotorcase Size mm M8 M10 Torque Nm 25 25 Torque ft lb 18 18 Stud Gearbox Housing Qty Pump 4 4 Front Cover Size mm M20 M24 Torque Nm 160 320 Torque ft lb 120 236 Socket Cap Head Screw Rotorcase Qty Pump 5 2 Bearing Housing Size mm M16 M20 Torque Nm 190 18...

Page 57: ...ump 2 2 Size mm M85 x 2 M105 x 2 Torque Nm 140 180 260 280 Torque ft lb 160 200 Locknut Inner Bearing Shaft Qty Pump N A 4 Size mm M120 x 2 Torque Nm 330 350 Torque ft lb 250 Socket Cap Head Screw Feet Qty Pump 4 4 Size mm M16 M20 Torque Nm 190 185 Torque ft lb 140 136 Socket Cap Head Screw Rear Cover Qty Pump 6 6 Gearbox Size mm M12 M16 Torque Nm 80 95 Torque ft lb 60 70 Hammer Drive Screw Namepl...

Page 58: ...onforming to AGMA Grade 5 ISO 220 SAE 90 With synthetic base stock Brand Petro Canada Purity FG Synthetic EP 220 Petro Canada Enduratex XL EP 220 or equivalent conforming to Governing Standard or equivalent conforming to Governing Standard Grease Governing Standard Conforming to NLGI 00 Containing EP additives Brand Petro Canada Precision XL EP00 or equivalent conforming to Governing Standard Appr...

Page 59: ...Page 59 Note For oil always add to the middle of the sight glass Oil Level Oil Level Oil Level Oil Level ...

Page 60: ... C12F St Steel Rotors 316 C12F St Steel Or Alloy 808 Rotor Retainers 316L St Steel Shafts 17 4 PH St Steel Setting Ring 316 St Steel Gearbox Cast Iron 250 304 St Steel Gearbox Cover Cast Iron 250 304 St Steel Foot Cast Iron 250 304 St Steel Pump Weights Lbs R3200X 790 R3800X R3900X 940 R4200X R5200X 2200 ...

Page 61: ...he pump Note 1 These lifting point have been designed to carry the weight of the pump only if the pump has been installed mounted these lifting point cannot be used 2 On lifting two certified lifting eyes must be used in conjunction with a correctly rated lifting sling Horizontal Port Vertical Ports Lifting Points Lifting Points WARNING ...

Page 62: ...R3900P 320 151 290 725 5 353 133 203 17 x 27 420 175 602 5 115 115 5 264 154 182 5 60 3 203 406 5 8 x 70 Size 7 CPP 4200X 520 162 520 1129 476 5 229 419 27 x 31 783 247 5 995 160 230 362 154 212 98 4 285 8 571 5 1 x 127 CPP 5200X 520 171 520 1174 476 5 229 419 27 x 31 783 247 5 1004 160 230 362 203 221 98 4 285 8 571 5 1 x 127 See dimensional drawing on following page Note Dimensions given are for...

Page 63: ...Page 63 ...

Page 64: ...ASE PUMP SPEED INCREASE PRODUCT TEMPERATURE X PRODUCT VISCOSITY TOO LOW INCREASE PUMP SPEED DECREASE PRODUCT TEMPERATURE X X X X X PRODUCT TEMPERATURE TOO HIGH COOL PRODUCT PUMPING CHAMBER X X PRODUCT TEMPERATURE TOO LOW HEAT PRODUCT PUMPING CHAMBER X X X X UNEXPECTED SOLIDS IN PRODUCT CLEAN THE SYSTEM FIT STRAINER ON SUCTION SIDE OF PUMP X X X X X X X DISCHARGE PRESSURE TOO HIGH CHECK FOR BLOCKAG...

Page 65: ...83 400 75 to 84 600 76 to 85 Size 7 250 86 5 to 89 300 85 5 to 91 4 325 88 1 to 92 Reference Only Values taken during testing at random viscosities and pressures Note values given can vary greatly depending on application and ambient noise Valures shown above should only be used as approximations ...

Page 66: ...ket Driven 5 mm Hexagon Allen Key Socket Driven 8 mm Hexagon Allen Key Socket Driven 10mm Hexagon Allen Key Socket Driven 14 mm Hexagon Allen Key Socket Driven 17 mm Torque Wrench Adjustable to Min 39 NM 28 76 ft lb Torque Wrench Adjustable to Min 107 NM 78 91 ft lb Torque Wrench Adjustable to Min 190 NM 140 ft lb Torque Wrench Adjustable to Min 330 NM 243 ft lb Depth Micrometer 0 25 mm 0 1 Feeler...

Page 67: ...ze 7 C Spanner To Suit Locknut Ø110 0 mm 4 331 C Spanner To Suit Locknut Ø120 0 mm 4 724 C Spanner To Suit Locknut Ø140 0 mm 5 512 Soft Faced Mallet Screwdriver Flat Blade Medium Circlip Pliers Internal Pin Punch Small Steel Hammer Small ...

Page 68: ...Page 68 7 0 Service History Pump Model Pump Serial No Date Comments ...

Page 69: ...Page 69 7 1 Notes The information contained in this document is correct at time of print but may be subject to change without prior notice ...

Page 70: ...x BN23 6PT United Kingdom Tel 44 1323 509211 Fax 44 1323 507306 wright eu idexcorp com Wright Flow Technologies Inc 406 State Street Cedar Falls Iowa 50613 USA Tel 319 268 8013 Fax 803 216 7686 wright usa idexcorp com www wrightflowtechnologies com Issue F 13 January 2020 ...

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