Alfalaval ALP 100 User manual

Screw pumps - ALP series
Sizes100-280Magnetic coupling
Operating Instructions
Product No.
Printed:
Book No:
OIA 04en
05/2015
9008785-02
Component
Description

Alfa Laval reserve the right to make changes at any time
without prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by: Alfa Laval S.p.A.
Marine & Diesel Equipment
Engineering & Supply Monza
20900 – Monza MB
Italy
© Copyright Alfa Laval SpA, 2015.
The original instructions are in English.

3
Contents
1 Warning signs in text 9
1.1 Warning signs 9
2 About this document 11
2.1 General information 11
2.2 Target groups 11
2.3 Symbols 11
2.4 Associated documents 11
3 Safety 13
3.1 Proper use 13
3.2 Safety information 13
3.3 Safety instructions for magnetic
coupling systems. 14
4 Labelling 15
4.1 Type code 15
4.2 Communication plate 16
5 Technical data 17
5.1 Operating limits 17
5.2 Required NPSH values 17
5.3 Weights 18
5.4 Dimensions 19
5.5 Capacity tables 21
5.6 Noise levels 22
5.7 Overowvalve 22
5.8 Materials 22
6 Function description 23
6.1 Structure 23
6.1.1 Standard direction of rotation: 24
6.1.2 Flow direction: 24
6.2 Magnetic coupling 24
6.3Overowvalve 24

4
7 Transportation, Storage and Disposal 25
7.1 Unpacking and checking the state of delivery 25
7.2 Lifting the pump/pump unit 25
7.3 Storage 26
7.4 Preservation 26
7.4.1 Removing the preservation 27
7.4.2 Disposing of the pump 28
8 Installation, removal and connection 31
8.1 Safety instruction on installation, removal
and connection 31
8.2 Installation 31
8.3 Installing the pump 31
8.4 Protect the pump against soiling 33
8.4.1 Connecting the pump to the pipe system 33
8.4.2 Connecting the motor 34
8.5 Removing the pump 35
9 Operation 37
9.1 Commissioning 37
9.2 Cleaning the pipe system 37
9.3 Filling the pump 38
9.4 Filling the pump via the suction or
pressure connection 38
9.5 Checking direction of rotation 39
9.6 Commissioning the pump 40
9.7 Taking pump out of operation 41
9.8 Recommissioning the pump 42
10 Maintenance 43
10.1 Safety instructions on maintenance & repairs 43
10.2 Required maintenance 43
10.3 Magnetic coupling 44
10.4 Ball bearing 44
10.5 Replacing the magnetic coupling 45
10.5.1 Dismantling the outer rotor 45
10.5.2 Dismantling the inner rotor 46

5
10.6 Installing the magnetic coupling 47
10.6.1 Mounting the inner rotor 47
10.6.2 Mounting the outer rotor 49
10.7 Replacing the ball bearing 50
10.7.1 Removing the ball bearing 50
10.7.2 Installing the ball bearing 51
11 Troubleshooting 53
11.1 Possible faults 53
11.2 Troubleshooting 53
12 Appendix 57
12.1Generaldrawings 57
12.2 Parts table 58
12.3 Tightening torques 58
12.4 Requiredtoolformaintenancework 59
EC Declaration of conformity 60
Notes 61
Notes 62

6

7
Study instruction manuals and observe
thewarningsbeforeinstallation,
operation, Service and maintenance.
Notfollowingtheinstructionscanresultin
serious accidents.
In order to make the information clear only foreseeable
conditions have been considered. No warnings are given,
therefore, for situations arising from the unintended usage
of the machine and its tools.

8

9
1.1 Warning signs
Pay attention to the safety instructions in this manual.
Below are denitions of the three grades of warning
signs used in the text where there is a risk for injury
to personnel.
DANGER indicates an imminently hazardous
situationwhich,ifnotavoided,willresultindeath
or serious injury.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous
situationwhich,ifnotavoided,mayresultinminor
or moderate injury.
NOTE indicates a potentially hazardous situation
which, if not avoided, may result in property
damage.
1 Warning signs in text
DANGER
!
!
WARNING
CAUTION
!
NOTE

10
1 Warning signs in text
1.1 Warning signs

11
2.1 General information
The operating instructions form part of the pump or of
the pump unit and must be kept for future reference.
Further more please observe the associated
documents.
2.2 Target groups
2 About this document
Target group Tasks
Operator-owner ●Keep these instructions available at the system site for future
reference.
●Ensure that employees read and observe these instructions and
the associated documents, in particular the safety instructions and
warnings.
●Observe additional system-specic directives and regulations.
Specialist personnel,
tters
●Read, observe and follow these instructions and the associated
documents, in particular the safety instructions and warnings.
2.3 Symbols
Symbol Meaning
Procedures mechanical installation
Procedures electrical installation
Check or fault table
Safety instructions for persons with pacemakers
Request for action
2.4 Associated documents
●ATEX supplementary instructions for operation in potentially explosive areas.
●Declaration of conformity according to EU Directive 2006/42/EC.
●Declaration of conformity according to EU Directive 94/9/EC.
●Manufacturer’s declaration as per EU Directive 97/23/EC.
●Operating instructions for the drive motor.

2 About this document
12
2.1 General information

13
3 Safety
3.1 Proper use
●Use the pump solely for transporting lubricating
liquids that are chemically neutral and that contain
no gas or solid components.
●Use the pump only within the performance
limitations specied on the rating plate and in the
“Technical data” section. In the case of operating
data that does not agree with the specications on
the rating plate, please contact the manufacturer.
●The pump is specically congured for the
operating pressure stated by the customer. In the
case of a signicant difference between actual and
congured operating pressure damages can occur
even within the stated performance limitations.
This applies both to notably higher as well as to
notably lower operating pressures. In case of any
doubt, please contact the manufacturer.
3.2 Safety information
NOTE
Thefollowinggeneralsafetyinstructionsmustbe
observed:
●No liability is accepted for damage arising through
non-observance of the operating instructions.
−Read the operating instructions carefully and
observe them.
−The operator-owner is responsible for the
observance of the operating instructions.
−Installation, removal and installation work may
only be carried out by specialist personnel.
●In order for the warranty to remain valid, corrective
maintenance carried out during the warranty
period requires the express permission of the
manufacturer.
●Observe the general regulations for the prevention
of accidents as well as the local safety and
operating instructions.
●Observe the valid national and international
standards and specications of the installation
location.

3 Safety
14
3.3 Safety instructions for magnetic coupling systems
●In case of systems with an increased potential of
danger to humans and/or machines the failure
of a pump may not lead to injuries or damage to
property.
−Always equip systems with an increased
potential of danger with alarm equipment.
−Maintain and check the protective/alarm
equipment regularly.
●The pumped liquids can be dangerous (eg. hot,
dangerous to health, poisonous, combustible).
Observe the safety regulations for handling
dangerous materials.
●Pumped liquid can be subject to high pressure
and can cause damage and/or personal injury
should leaks occur.
3.3 Safety instructions for magnetic
coupling systems.
Magnetic elds from magnetic coupling systems
(MCS) can inuence the function and operational
safety of electrical and electronic devices. The
following safety instructions must be observed.
Additional safety instructions for magnetic
coupling systems:
●Keep the MCS away from pacemakers. There is a
danger to life!.
−Under no circumstances may persons with
pacemakers perform installation, dismantling
or maintenance work.
●Persons with pacemakers must comply with the
following safe distances to the MCS:
−3 m distance to the openly accessible MCS.
−1 m distance to pump units with installed MCS.
●Do not bring the MCS in the immediate area of PCs,
data carriers and other electronic components.
●Keep the MCS away from clocks, magnetized
tools and measuring equipment as well as all
magnetizable parts.
●Do not bring both the MCS parts together, as this
can destroy the magnetic coupling system.

15
4 Labelling
4.1 Type code
1Model
2Size
3Seal type
4 Overow valve
5Completion
6Motor size
Figure 1 Type code
Item Designation Type
1 Model ALP: Single pump
2 Size Corresponds to ow rate in [l/min] at 1450 min-1
3 Seal type B: Mechanical seal of hard material
D: Magnetic coupling
4Overow valve
Opening at differential pressure [bar]
A: 6 ± 10 %
B: 10 ± 10 %
5 Completion
A: Pump with free shaft end
B: Pump unit for vertical mounting, with pump bracket and
coupling.
C: Pump unit for horizontal mounting, with pump bracket, pump
bracket foot and coupling.
D: Pump unit for vertical mounting, with pump bracket, coupling
and motor.
E: Pump unit for horizontal mounting, with pump bracket, pump
bracket foot, coupling and motor.
6 Motor size
90
100
112
132
160
180
Table 1 Type code
ALP-0115-DAA10
0
1
2
3
4
5
6

4 Labelling
16
4.2 Communication plate
1
2
3
4
5
6
1Pump type
2Serial number
3Year of construction
4Item number
5Temperature max.
6Differential pressure max.
Figure 2 Rating plate
4.2 Communication plate

17
5 Technical data
5.1 Operating limits
Size 100 - 280
OverowvalveA OverowvalveB
Differential pressure max. [bar] 5.4 9
End pressure max. [bar] 16 16
Valve opening pressure [bar] 6 ± 10 % 10 ± 10 %
Temperature max. [°C] 155 155
Temperature min. [°C]
for pump materials -20 -20
Viscosity min. - max. [mm2/s] 1.4 - 10000 1.4 - 10000
Rotation speed [min-1]
at 50 Hz 2900 2900
at 60 Hz 3500 3500
Table 1 Operating limits
5.2 Required NPSH values
The following table lists the required NPSH values
during operation with a low-volatile liquid such as
lubricating oil or hydraulic liquid. When liquids have
a readily volatile component content, the required
NPSH values increase notably:
●When the pumped liquid contains water (e.g.
Heavy fuel oil), the values in the table have
to be increased by the vapour pressure of the
water at the specied operating temperature.
The required NPSH values also need to be
increased if there are gas contents, regardless of
whether it is dissolved or not. In case of any doubt,
please contact the manufacturer.

5 Technical data
18
Size Viscosity
[mm2/s]
NPSH value [mWC] at
Rotation speed [min-1]Size Viscosity
[mm2/s]
NPSH value [mWC] at
Rotation speed [min
-1]
1450 1750 2900 3500 1450 1750 2900 3500
ALP
100
6 2.0 2.0 2.8 3.4
ALP
215
6 2.2 2.4 4.0 5.2
37 2.0 2.2 3.2 3.8 37 2.4 2.7 4.5 6.0
152 2.4 2.6 3.8 4.6 152 2.8 3.2 5.5 7.5
380 2.9 3.1 4.6 5.7 380 3.4 3.9 6.9 9.5
ALP
115
6 2.0 2.1 2.7 3.2
ALP
230
6 2.1 2.4 4.0 5.3
37 2.0 2.2 3.0 3.6 37 2.4 2.7 4.5 6.0
152 2.4 2.5 3.6 4.4 152 2.8 3.2 5.5 7.5
380 2.8 3.0 4.4 5.4 380 3.4 3.9 6.9 9.5
ALP
165
6 2.0 2.1 2.9 3.6
ALP
280
6 2.3 2.6 4.5 6.1
37 2.1 2.3 3.3 4.1 37 2.5 2.9 5.1 7.0
152 2.5 2.7 4.0 5.0 152 3.0 3.5 6.3 8.8
380 2.9 3.2 4.9 6.1 380 3.6 4.2 8.0 11.4
Table 2 Required NPSH values
5.3 Weights
Motor
size
Magnet
power[Nm]
Size Weight of pump bracket
footwithscrews[kg]
100
115
165
215
230
280
Weight of pump with free shaft end [kg]
20.2 32.3 36.1
Weight of pump bracket with magnetic coupling and screws [kg]
90 20 7.9 - - 0.5
100/112 30 8.9 - - 1.6
40 -11.4 11.4 1.6
132 40 9.5 - - 2.7
60 - 13.0 13.0 2.7
160 60 -15.4 15.4 1.9
100 - - 20.1 1.9
180 100 - - 20.2 1.9
Table 3 ALP weights with magnetic coupling
5.2 Required NPSH values

5 Technical data
19
5.4 Dimensions
Size Pump [mm] Shaft end [mm]
L1 L2 L3 L4 D1 D2 D3 S1 Z1 g1/
g2 B1 B2 d l t u
100 - 115 59 14 129 272.5 160 138 75 11 4110 20 20 19 43 - -
165 - 215 57 17 140 333.5 230 200 110 14 4 122.5 20 20 28 47 - -
230 - 280 63.5 18 178.5 363.5 230 200 110 14 4 140 20 20 28 47 - -
Table 4 Dimensions ALP pump
Size Motor
size
Magnet
power
[Nm]
Pump unit [mm]
LP LL LM* LG** L5 L6 L7 L8 L9 H1 H2 B3 B4 S4
100-
115
90 75/20 272.5 140 * ** 60 90 19 15 190 12 112 210 180 Ø11
100/
112 75/30 272.5 148 * ** 60 97 39 21 178 15 132 250 220 Ø13
132 75/40 272.5 196 * ** 80 116 40 20 205 18 160 290 260 Ø13
165-
215
100/
112 75/40 333.5 175 * ** 60 97 39 21 216 15 132 250 220 Ø13
132 75/60 333.5 210 * ** 80 116 40 20 230 18 160 290 260 Ø13
160 75/60 333.5 256 * ** 110 150 45 20 241 22 180 340 300 Ø18
230-
280 132 75/60 363.5 210 * ** 80 116 40 20 268.5 18 160 290 260 Ø13
230 160 75/60 363.5 256 * ** 110 150 45 20 279.5 22 180 340 300 Ø18
280 160 110/100 363.5 228 * ** 110 150 45 20 251.5 22 180 340 300 Ø18
230-
280 180 110/100 363.5 228 * ** 110 150 45 20 251.5 22 180 340 300 Ø18
Table 5 Dimension pump unit with magnetic coupling.
*Depends on motor model
** LG=LP+LL+LM
5.3 Weights

5 Technical data
20
5.4 Dimensions
D2
S1/Z1
L1
L4
D3
L3
h7
lL2
D1
d
j6
g2
B1
g1
B2
L8
L6
LP LM
L5
LG
LL
L7
L9
B3
H2
B4
H1
S4
Figure 1 Dimensional drawing of ALP pump and pump unit.