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Causes and removal of operational faults

760.0003 GB - 151 999

BA-2011.04

Series AE.N
Construction Type RG

47

12 Causes and removal of operational faults

Discuss with the manufacturer any disturbances not contained in the following table or that cannot be
traced to the causes listed below.
Each possible disturbance is labeled with a letter in the table below. Reference this letter in the table
of disturbances to find the corresponding cause and correctional measure.

Refer to letter f in the following table to reduce noise and vibrations.

Letter

Disturbance

a:

Pump does not start

b:

Pump does not generate suction

c:

Capacity not reached

d:

Delivery head not reached

e:

Pumping is not uniform

f:

Pump is loud or vibrates

g:

Pump has seized or no longer
pumps

h:

Motor gets too warm

i:

Stator wears out prematurely

k:

Shaft seal leaks

Tab. 11 Overview of potential disturbances

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Содержание AE1N200-RG

Страница 1: ...umentation for operational data dimensions and other additional information Order No Pump ID No Machine No Pump model Edition BA 2011 04 ALLWEILER AG Bottrop plant Print No 151 999 P O Box 200123 46223 Bottrop VM No 760 0003 GB Kirchhellener Ring 77 79 46244 Bottrop Germany Telephone 49 0 2045 966 60 Fax 49 0 2045 966 679 E mail service allweiler de Internet www allweiler com Subject to technical ...

Страница 2: ...h the pump is integrated are not provided here These must be provided by the persons who are responsible for planning and constructing the system system manufacturer Specific notices of this type regarding operation and maintenance of the overall system in which the pump is integrated have precedence over the pump manufacturer s notices The systems manufacturer must comply with operational limits ...

Страница 3: ...es 6 3 8 Danger of pumped liquid 6 4 Design and function 7 4 1 Application and area of usage 7 4 2 Labeling 7 4 2 1 Nameplate 7 4 2 2 Pump model label 7 4 3 Performance data 7 4 4 Design 7 4 4 1 Structural design 7 4 4 2 Bearing and lubrication 7 4 4 3 Shaft seal 7 4 4 4 Dimensions branch positions flanges 7 4 4 5 Noise level 7 4 4 6 Non ionizing radiation 7 4 4 7 Operation 7 4 5 Pump unit design ...

Страница 4: ...p sizes 100 2700 25 10 1 8 Removing the drive shaft on pump size 5000 25 10 1 9 Removing the hollow shaft and spur gears from pump size 500026 10 1 10 Removing the running gear seal 26 10 2 Assembling the progressing cavity pump 26 10 2 1 Installing the drive shaft and spur gears on pump sizes 100 2700 26 10 2 2 Installing the hollow shaft and spur gears on pump size 5000 28 10 2 3 Installing the ...

Страница 5: ...clamp 32 Fig 18 Canting and shearing off the joint clamp 32 Fig 19 Installing running gear seal 35 Fig 20 Position of running gear seal 35 Fig 21 Installing running gear seal 36 Fig 22 Sectional drawings of series AE N RG construction type sizes 100 2700 43 Fig 23 Sectional drawings of series AE N RG construction type 44 Fig 24 Sectional drawings of series AE N RG construction type size 5000 45 Fi...

Страница 6: ...Listing of Tables vi Series AE N Construction Type RG BA 2011 04 760 0003 GB 151 999 ...

Страница 7: ... Declaration of conformity Standards conformity ATEX supplemental instructions Instructions for operation in potentially explosive atmospheres Tab 2 Other applicable documents 1 3 Warning notices and symbols Several names and symbols are used in the operating instructions to represent hazards and safety regulations Together with written safety notices the safety symbols are designed to draw attent...

Страница 8: ...ctions at all times In addition to the operating instructions other instructions related to the German Work Protection Law ArbSchG and Work Equipment Ordinance AMBV must also be provided All signs containing safety and operating notices must be kept in readable condition at all times Signs that are damaged or become unreadable must be replaced immediately 1 7 Inspection All pumps are subjected to ...

Страница 9: ...he system There is no assurance that third party parts are designed to withstand operating loads and safety specifications We do not approve the use of any parts or special equipment that we did not deliver 2 3 Avoiding common mistakes examples Always observe the pump s operational limits regarding temperature pressure capacity viscosity and speed order data sheet If pumping liquids loaded with so...

Страница 10: ...y be operated only when all safety devices are fully functional No safety equipment may be removed or taken out of operation before or during operation of the system Before switching on the system ensure that no one will be endangered by starting of the system The system must be regularly checked for visible damage and functionality of the safety equipment 2 5 3 Safety at the place of installation...

Страница 11: ...rer approved accessories promote safety Use of other parts will nullify liability for any resulting consequences 2 8 Impermissible operating methods Operational safety of the delivered machine is ensured only through proper use as described in Section 1 of the operating instructions Never exceed the limit values specified in the data sheet 2 9 Protective clothing Protective gloves Wear protective ...

Страница 12: ...nergy through high voltage and through short circuits and overloads Only electrical technicians may perform work on the electrical power supply The machine s electrical equipment must be inspected on a regular basis Loose connections and charred cables must be removed immediately Proper earthing must be provided whenever there is the potential for electrostatic charges If it is necessary to work o...

Страница 13: ...ents are the rotor and stator Drive torque is transferred via the drive shaft stub shaft and universal joint shaft to the rotor and via a gear stage to the worm shaft The discharge casing stator and stuffing housing are held together by means of external housing connection screws clamp bolts 4 4 2 Bearing and lubrication Both sides of the universal joint shaft have liquid sealed encapsulated pin j...

Страница 14: ...ive Driven by electric motors with or without explosion protection gear motors or variable gear motors Other drive types such as with a V belt are possible 4 5 2 Shaft coupling and safety guarding Shaft coupling according to DIN 740 A safety guard according to DIN EN 809 is attached whenever pump base plate and shaft coupling are delivered together Warning Danger of being caught wound drawn in and...

Страница 15: ... pump unit so that they are precisely balanced during lifting Make sure that the pump unit is transported safely and in a stable position to and at the place of installation Make sure that it cannot tip over due to top heaviness Notice When receiving the pump inspect it for transport damages Immediately report any damages 5 3 Preserving progressing cavity pumps and placing them into storage 5 3 1 ...

Страница 16: ...e universal joint collar stator and seals Internal preservatives can be removed by rinsing the pump with the pumped liquid But if contamination in the pumped liquid is impermissible the pump must be disassembled and the metal parts cleaned with an approved cleaning agent Choose cleaning agents appropriate for the area of usage Cleaning agents page 11 Dispose of preservatives according to local reg...

Страница 17: ...eaning ether cleaning solvent diesel fuel petroleum alkaline cleaner Tab 6 Cleaning agents 5 4 Disposal Plastic parts and elastomers can be conta minated by toxic or radioactive pumped liquids in such a way that cleaning is not adequate Warning Danger of poisoning or environmental damage by pumped liquid or oil Use personal protective clothing when performing any work on the pump Before disposing ...

Страница 18: ...d with suitable screws refer to unit drawings for connection dimensions Caution If the base plate is supported only at isolated points this will cause the pump unit to sag in the center or warp This will affect alignment of the pump unit and can lead to high noise emissions and damage 6 2 3 Fastening the pump unit to the concrete foundation After aligning the pump unit on the foundation uniformly ...

Страница 19: ...drawings on page 43 After loosening of the screws the foot of the discharge casing and the shaft sealing housing may not be tilted nor spring nor be under pressure If major deviations are found loosen the base plate attachment and remove the tension by refilling 6 4 Coupling Fine adjustment of the coupling Danger Life threatening danger from moving parts Shut off the motor s power supply and lock ...

Страница 20: ...t together at the place of installation establish the coupling connection as follows 1 Apply a very thin layer of molybdenum disulfide such as Molykote to the ends of the pump and drive shaft insert keys 2 Use a hoisting device to hoist the pump and motor sides of the coupling until the shaft end overlaps the coupling hub If a hoisting device is not available warming the halves of the coupling to ...

Страница 21: ...esidual items from assembly such as screws nuts weld beads or pieces of metal will destroy the pump s internal parts Warranty claims of any kind are invalidated whenever damages are caused by such residual items Flange gaskets may not protrude inward Blank flanges plugs protective film and or protective coatings on flanges and sealing strips must be completely removed 6 7 Safety and inspection equ...

Страница 22: ...Caution A professional electrician must attach the coupled drive motor s power supply cable in accordance with the connection diagram provided by the motor manufacturer All VDE regulations and regulations from the local power supply company must be obeyed Hazards associated with electrical power must be eliminated An emergency off switch must be installed ...

Страница 23: ... n directional arrow on the pump s nameplate Improper direction of rotation can damage the pump To check the direction of rotation turn the pump on and immediately back off 7 2 Bringing the pump into operation 7 2 1 Starting Caution Open all blocking devices on the suction and pressure sides before starting 7 2 2 Drive Switch the motor on Caution Observed the characteristics of the specific drive ...

Страница 24: ...ed to transport food or if it will be used in the cosmetics or pharmaceutical industries special cleaning disinfection and flushing agents must be used in conjunction with the proper procedures Make sure that the regular pumped liquids do not become contaminated with residuals of the cleaning and or flushing disinfection agents We recommend using only liquids that should they contaminate the pumpe...

Страница 25: ...or the following parts Rotor stator Wear to the rotor and or stator is manifested in the form of lower pump capacity and lower pressure Maintenance can be planned when this is noticed i e it is not necessary to immediately replace the rotor and or stator For detailed information about maintenance procedures and intervals for other components please refer to section 9 page 20 and section 10 page 23...

Страница 26: ...nd any others The joints have lifetime lubrication However if the pump must be opened for other reasons we recommend checking the joint collar for leaks and replacing the joint oil after 8000 operating hours The following table shows the relationship between the pump size and the oil volume in cubic centimeters Refer to section 10 page 23 for information on changing the joint oil Pump size Oil vol...

Страница 27: ...se a packing extractor with a flexible shaft Then carefully clean the stuffing box area and the shafts near the packing rings Worn shafts must be replaced see Section 10 1 page 23 Installing the packing rings Caution Use only the packing rings specified in our pump parts lists Refer to the pump parts list for the dimensions and required quantity of the pre pressed packing rings Caution Pre pressed...

Страница 28: ...enly immediately loosen the stuffing box gland and repeat the run in process Remove any leakage between the stuffing box casing and the bearing bracket Eliminate any possibility of injury and environmental damage caused by leaks of hazardous materials 9 1 5 2 Running gear seal The running gear seal is maintenance free In the event of strong wear induced leaks replace the running gear seal section ...

Страница 29: ... repairs These instructions describe the most important disassembly and assembly tasks The assembly steps described in each of the sections must be followed consistently 10 1 1 Disassembling the progressing cavity pump Perform the following tasks before disassembly 1 Run the pumped liquid out of the suction casing 2 Disconnect the motor s power cord Prevent the motor from switching on unexpectedly...

Страница 30: ...e joint shaft 307 Notice Use a collection container 7 Drive the joint sleeve 304 over the collar of the universal joint shaft 307 Do not deflect the universal joint shaft 307 see image below Fig 8 Removing the joint sleeve 8 Knock out the joint bolt 301 9 Use a brass pin punch to drive out half way both bushes for the joint bolt 303 Deflect the universal joint shaft 307 to do this see image below ...

Страница 31: ... and 10 1 4 1 Punch out retainer pin 123 from stub shaft 125 2 Pull off stub shaft 125 10 1 7 Removing the drive shaft and spur gears on pump sizes 100 2700 Remove the drive shaft and spur gears after removing the universal joint shaft 307 stub shaft 125 and worm shaft 50 See Sections 10 1 4 10 1 5 and 10 1 6 1 Loosen screw connections 38 39 245 and press the stuffing box casing 36 204 from the be...

Страница 32: ...rive the tapered roller bearing 103 104 and shaft seal ring 112 120 from the bearing bracket 110 bearing cover 111 68 and hollow shaft 90 13 Remove key 16 14 Loosen circlip 23 and pull out of the groove 15 Press shaft 20 from bearing bracket 110 16 Remove key 24 spray washer 30 17 Loosen circlip 22 and pull out of groove 18 Pull spur gear 14 and 27 out of the bearing bracket 110 together 19 Use a ...

Страница 33: ...and 27 into each other with opposing key grooves insert them into the bearing housing 110 with the collar pointing towards the pump see figure below Fig 10 Installation position of the spur gears 7 Use a suitable section of pipe to push the groove ball bearings 26 104 from the drive side over the bearing outer ring and into the bearing bracket 110 First lightly oil the bearing seat surface 8 Inser...

Страница 34: ...into the clean seat of the bearing bracket 110 or bearing cover 111 68 3 On the stuffing box side the shaft seal 29 must close flush with the seat of the bearing bracket 110 Notice The sealing lip with the shaft seal ring s hose spring must always face the side being sealed pointing inward Use a suitable pressing die to press it inward It is extremely important that the pressing force be applied a...

Страница 35: ... rollers Support the hollow shaft with a suitable tool 18 Lightly oil the threads of the bearing nut 116 and use a hook wrench to turn bearing nut 116 onto the hollow shaft 90 Caution Tapered roller bearings 103 and 104 must be carefully adjusted against each other via the bearing nut 116 Adjustment refers to prestressing and adjustment of the bearing clearance Improper adjustment will lead to bea...

Страница 36: ...seal 109 to the bearing bracket 110 25 Warm spray washer 114 to approximately 150 C and slide it onto the seat of the hollow shaft 90 until it stops 26 Screw the screw plug 10 with sealing strip 11 into the bearing bracket 110 27 Fill bearing bracket 110 with gear oil 17 Refer to Section 9 1 4 for filling volume and oil type 28 Coat sealing surface on bearing bracket 110 with seal 132 29 Use the h...

Страница 37: ...ill with ALLWEILER special joint oil type BL or oil 1810 460 from Tribol Lubricants GmbH of Mönchen gladbach Germany Filling volume see table section 9 1 2 9 Check if the joint clamp s 306 bent strap is contacting the joint clamp seal If it is not apply pressure with a commercially available pliers see next image Fig 14 Apply pressure to the joint clamp strap on the joint clamp seal 10 Place the j...

Страница 38: ...efully rebending it Hammering or striking the joint clamp seal is not acceptable because this may cause damage to the collar Notice The clamping tool cannot be used to shear off joint clamps made of Hastelloy After canting at the joint clamp seal use metal shears to shear off the joint clamp deburr the cut edges see following image 10 2 3 2 Tightening with clamping tool PoK It II If using the PoK ...

Страница 39: ...until it stops Caution First lightly oil the bore of the hollow shaft 90 Do not use lubricant that contains MoS2 5 Rotate the drive shaft 118 so that the cross hole in the drive shaft 118 and the cross hole in the shaft 20 are on one axis and the worm or worm blades of the universal joint shaft 307 mesh with the worms of the worm shaft 50 6 Clean and lightly oil the seat position of the shrink dis...

Страница 40: ...action and centrifugal forces during rotation causes the lubricant to move into the sealing gap thereby providing adequate lubrication and cooling effects and avoiding cold fusion of the sealing surfaces This generally causes a physically conditioned lubricating film to be visible on the outer sealing gap this should not be perceived as a leak Instead it indicates that the mechanical seal is worki...

Страница 41: ...Notice The image below shows the proper position of the running gear seal 79 Correct Incorrect Incorrect Fig 20 Position of running gear seal Caution Clean the sliding surfaces of the running gear seal 79 and coat with oil preferably with a saturated suede cloth 14 Press the seal sleeve 71 through the radial ball bearing 75 and into the seal casing 70 First apply a thin coating of oil to the surfa...

Страница 42: ...de running gear cartridge onto the shank of the worm shaft 50 To facilitate installation surfaces over which O rings glide may be lubricated with silicon oil polydiol or lubricating soap for example Caution Do not use regular oil Notice Observe the proper position of the retainer 72 19 Use screwed connections 81 82 83 to fasten the running gear cartridge to the stuffing housing 40 20 Press the sea...

Страница 43: ...611 and hexagon nuts 609 to screw into place the pressure casing 504 bracket 612 if present stator 402 and stuffing housing 40 Tighten hexagon screws uniformly 6 Tighten hexagon screws 613 if present Caution Before bringing the pump into operation turn the pump a full rotation by rotating the drive shaft 118 by hand in order to make sure that the universal joint shaft 307 and worm shaft 50 move fr...

Страница 44: ...tion For safety reasons stock and use only original spare parts provided by Allweiler Refer to the information provided under Section 2 7 page 5 When ordering spare or reserve parts always provide the following information Pump number Pump model Part number Description and quantity of the part or ID number and quantity Notice The pump number and pump model are stamped onto the nameplate Refer to t...

Страница 45: ...h multi piece stator 7 with multi piece stators 8 with AE N 5000 only Part No Description Repair kit Quantity Remarks 10 Screw plug 1 11 Sealing tape R 12 Circlip 1 1 13 Venting and ventilation filter 2 14 Spur gear R 1 16 Key 1 17 Gear oil see Section 9 1 4 R 20 Shaft R 1 21 Groove ball bearing R 1 22 Circlip 1 23 Circlip 1 24 Key 1 25 Sealing cap 1 26 Groove ball bearing R 1 27 Spur gear R 1 28 ...

Страница 46: ...ass 1 61 Seal 1 63 Supporting washer 1 8 65 O ring R 2 8 66 Hexagon screw 8 8 67 Spring ring 8 8 68 Bearing cover 1 8 69 Bearing cover seal 1 8 70 Seal housing 1 71 Seal sleeve 1 72 Retainer 1 73 Sealing cap 1 74 Bearing nut 1 75 Radial ball bearing R 1 76 Circlip 1 77 Spacer ring 1 78 Shaft seal ring R 1 79 Running gear seal R r 1 80 O ring R 1 81 Stud bolt 4 82 Sealing material 83 Hexagon nut 4 ...

Страница 47: ... 113 Spacer ring 1 1 114 Spray washer 1 116 Bearing nut 1 8 118 Drive shaft R 1 120 Shaft seal ring R 1 121 Circlip 1 123 Retainer pin 1 1 125 Stub shaft R 1 1 131 Bearing cover 1 132 Seal R 139 Hexagon head screw 6 2 141 Lubrication paste 201 Stud bolt 2 202 Self locking nut 2 203 Stuffing box gland half 2 204 Stuffing box casing 1 207 Gland packing R r 5 218 O ring 1 245 Stud bolt 8 4 301 Joint ...

Страница 48: ...ng 1 505 Suction casing 1 601 Nameplate 1 602 Round head grooved pin 4 603 Information plate Start up 1 604 Information plate Suction 1 605 Information plate Discharge 1 606 Stud bolt 4 607 Hexagon nut 4 608 Spring ring 4 609 Hexagon nut 4 610 Washer 4 611 Clamp bolt 4 612 Support piece 1 7 612 Support piece 1 7 627 Information plate Danger of injury 1 631 Fastening piece 2 7 632 Hexagon nut 2 7 6...

Страница 49: ... 100 2700 760 0003 GB 151 999 BA 2011 04 Series AE N Construction Type RG 43 11 2 Sectional drawing for series AE N RG construction type sizes 100 2700 Fig 22 Sectional drawings of series AE N RG construction type sizes 100 2700 Part 304 secured with one center punch mark A ...

Страница 50: ...3 GB 151 999 11 3 Sectional drawing for series AE N RG construction type Fig 23 Sectional drawings of series AE N RG construction type Multi piece stator with non uniform elastomer wall thickness Multi piece stator with uniform elastomer wall thickness Shaft seal in cover by sizes 1450 and 2700 Thrust bearing by size 2700 ...

Страница 51: ...e size 5000 760 0003 GB 151 999 BA 2011 04 Series AE N Construction Type RG 45 11 4 Sectional drawing for series AE N RG construction type size 5000 Fig 24 Sectional drawings of series AE N RG construction type size 5000 Part 304 secured with one center punch mark A ...

Страница 52: ...type 46 Series AE N Construction Type RG BA 2011 04 760 0003 GB 151 999 11 5 Sectional drawing for series AE N RG construction type Fig 25 Sectional drawings of series AE N RG construction type bearing drive shaft size 5000 bearing worm shaft size 5000 drive seal ...

Страница 53: ...letter in the table below Reference this letter in the table of disturbances to find the corresponding cause and correctional measure Refer to letter f in the following table to reduce noise and vibrations Letter Disturbance a Pump does not start b Pump does not generate suction c Capacity not reached d Delivery head not reached e Pumping is not uniform f Pump is loud or vibrates g Pump has seized...

Страница 54: ...ough pumped liquid is present on the suction side 10 Increase speed with low viscous liquids and large suction volume 11 Reduce speed with viscous liquids danger of cavitation 12 Check longitudinal tolerance of joint pins joint bush may be improperly installed 13 Check for foreign objects in the pump disassemble pump remove foreign objects replace any defective parts 14 Stator and rotor are worn D...

Страница 55: ...Clearance certificate 760 0003 GB 151 999 BA 2011 04 Series AE N Construction Type RG 49 13 Clearance certificate Fig 26 Clearance certificate ...

Страница 56: ...51 999 14 Declaration according to EC machinery directive Declaration of conformity according to EC machinery directive Notice The following declaration contains neither serial numbers nor signatures The original declaration with the name of the documentation officer and signatures is included with each pump ...

Страница 57: ...nenrichtlinie 2006 42 EG Machinery Directive 2006 42 EC Directive 2006 42 CE relative aux machines Niederspannungsrichtlinie 2006 95 EG Low Voltage Directive LVD 2006 95 EG Directive Basse Tension DBT 2006 95 EG EMV Richtlinie 2004 108 EG Electromagnetic Compatibility EMC Directive 2004 108 EG directive sur la Compatibilité électromagnétique CEM 2004 108 CEE Dokumentationsverantwortlicher person a...

Страница 58: ...52 Series AE N Construction Type RG BA 2011 04 760 0003 GB 151 999 ...

Страница 59: ...760 0003 GB 151 999 BA 2011 04 Series AE N Construction Type RG 53 ...

Страница 60: ...R AG P O Box 20 01 23 46223 Bottrop Kirchhellener Ring 77 79 46244 Bottrop Germany Tel 49 0 2045 966 60 Fax 49 0 2045 966 679 E mail service allweiler de Internet http www allweiler com Edition BA 2011 04 Print No 151 999 VM No 760 0003 GB ...

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