Alfalaval FM-OS User manual

3010-0009
ESE02171-EN4 2016-10
Original manual
Instruction Manual
FM-OS Centrifugal Pump

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC Declaration of Conformity ....................................................................... 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 6
3. Installation .............................................................................................. 7
3.1. Unpacking/delivery ............................................................................... 7
3.2. Installation ......................................................................................... 8
3.3. Pre-use check ..................................................................................... 10
3.4. Recycling information ............................................................................. 11
4. Operation ............................................................................................... 12
4.1. Operation/control ................................................................................. 12
4.2. Trouble shooting .................................................................................. 13
4.3. Recommended cleaning ......................................................................... 14
5. Maintenance ........................................................................................... 15
5.1. General maintenance ............................................................................. 15
5.2. Dismantling - single shaft seal ................................................................... 17
5.3. Dismantling - flushed shaft seal ................................................................. 18
5.4. Assembly - single shaft seal ..................................................................... 19
5.5. Assembly - flushed shaft seal ................................................................... 20
5.6. Assembly - new shaft ............................................................................ 20
6. Technical data ......................................................................................... 21
6.1. Technical data ..................................................................................... 21
6.2. Torque specifications ............................................................................. 22
6.3. Weight (kg) ........................................................................................ 22
6.4. Noise emission .................................................................................... 23
7. Parts list and service kits ............................................................................ 25
7.1. Drawings ........................................................................................... 25
7.2. FM-OS Centrifugal pump, single shaft seal .................................................... 26
7.3. FM-OS Centrifugal pump, flushed shaft seal ................................................... 28
3

1 EC Declaration of Conformity
Revision of Declaration of Conformity 2009-12-29
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Pump
Designation
FM-OS
Type
From serial number 10.000 to 1.000.000
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
The person authorised to compile the technical file is the signer of this document
Global Product Quality Manager
Pump, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name
Kolding 2013-12-03
Place Date Signature
4

2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
Always read the manual before using the pump!
2.1 Important information
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the pump.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
Dangerous electrical voltage:
Caustic agents:
5

2 Safety
All warnings in this manual are summarised on this page.
Pay special attention to the instructions below so that serious personal injury and/or damage to the pump are avoided.
2.3 Safety precautions
Installation:
Always read the technical data thoroughly. (See chapter 6 Technical data) !
Always use a lifting crane when handling the pump.
Pump without impeller screw:
Always remove the impeller before checking the direction of rotation.
Never start the pump if the impeller is fitted and the pump casing is removed.
Pump with Impeller screw:
Never start in the wrong direction of rotation with liquid in the pump.
Always have the pump electrically connected by authorised personnel. (See the motor instruction) !
Operation:
Always read the technical data thoroughly. (See chapter 6 Technical data) !
Never touch the pump or the pipelines when pumping hot liquids or when sterilising.
Never run the pump with both the suction side and the pressure side blocked.
Never run the pump when partially installed or not completely assembled
Necessaryprecautions must be taken if leakage occurs as this can lead to hazardous situations.
Always handle lye and acid with great care.
Never use the pump for products not mentioned in Alfa Laval pump selection program.
The Alfa Laval pump selection program can be acquired from your local Alfa Laval sales company.
Maintenance:
Always read the technical data thoroughly. (See chapter 6 Technical data) !
Never service the pump when it is hot.
Never service the pump if pressurised.
Always use Alfa Laval genuine spare parts.
Motors with grease nipples:
Remember lubrication according to information plate/label on the motor.
Always disconnect the power supply when servicing the pump.
Transportation:
Transportation of the pump or the pump unit:
Never lift or elevate in any way other than as described in this manual
Always drain the pump head and accessories of any liquid
Always ensure that no leakage of lubricants can occur
Always transport the pump in its upright position
Always ensure that the unit is securely fixed during transportation
Always use original packaging or similar during transportation
6

3 Installation
3.1 Unpacking/delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete pump.
2. Delivery note.
3. Instruction manual.
4. Motor instructions.
5. Test certificate, IF ORDERED!
Step 2
Remove any possible packing materials from the inlet and the
outlet.
Avoid damaging the inlet and the outlet.
Avoid damaging the connections for flushing liquid, if supplied.
Step 3
Inspect the pump for visible transport damage.
Step 4
Always remove the shroud, if fitted, before lifting the pump.
7

3 Installation
Study the instructions carefully and pay special attention to the warnings! Always check the pump before operation.
- See pre-use check in section 3.3 Pre-use check.
3.2 Installation
Step 1
!
Always read the technical data thoroughly. (See chaper 6 Technical data)
Always have the pump electrically connected by authorised personnel. (see the motor instructions).
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
WARNING:
Alfa Laval recommends the installation of lockable repair breaker. If the repair breaker is to be used as an emergency stop,
the colours of the repair breaker must be red and yellow.
Caution:
The pump does not prevent back flow when intentionally or unintentionally stopped. If back flow can cause any hazardous
situations, precautions must be taken e.g. check valve to be installed in the system preventing that described above.
Note
In case of shaft seal leakage, the media will drip from the slot in the bottom of the adaptor. In case of shaft seal leakage, Alfa
Laval recommends placing a drip tray underneath the slot to collect the leakage.
Step 2
Ensure that there is sufficient clearance around the pump.
Step 3
Check that the flow direction is correct.
Step4
1. Ensure that the pipelines are routed correctly.
2. Ensure that the connections are tight.
Remember seal rings!
TD202-037_1 Few bends
Correct!
8

3 Installation
Study the instructions carefully and pay special attention to the warnings! Always check the pump before operation.
- See pre-use check in section 3.3 Pre-use check.
Step 5
Avoid stresses to the pump.
Pay special attention to:
-Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
Risk of damage
9

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Check the direction of rotation of the impeller before operation.
- See the indication label on the pump.
3.3 Pre-use check
Step 1
!
Always remove the impeller before checking the direction of rotation.
!
Never start the pump if the impeller is fitted and the pump casing is removed.
Step 2
Dismantle the pump in accordance with instructions in section 5.2
for single shaft seal and 5.3 for flushed shaft seal.
Step 3
1. Start and stop the motor momentarily.
2. Ensure that the direction of rotation of the stub shaft (7) is
anticlockwise as viewed from the inlet side.
See the indication label!
Step 4
Assemble the pump in accordance with instructions in section 5.4 for single shaft seal and 5.5 for flushed shaft seal.
10

3 Installation
3.4 Recycling information
• Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.
- Wood and cardboard boxes can be reused, recycled or used for energy recovery.
- Plastics should be recycled or burnt at a licensed waste incineration plant.
- Metal straps should be sent for material recycling.
• Maintenance
- During maintenance, oil and wear parts in the machine are replaced.
- All metal parts should be sent for material recycling.
- Worn out or defective electronic parts should be sent to a licensed handler for material recycling.
- Oil and all non-metal wear parts must be taken care of in accordance with local regulations.
• Scrapping
- At end of use, the equipment must be recycled according to relevant, local regulations. Beside the equipment itself, any
hazardous residues from the process liquid must be taken into consideration and dealt with in a proper manner. When in
doubt, or in the absence of local regulations, please contact your local Alfa Laval sales company.
11

4Operation
Study the instructions carefully and pay special attention to the warnings!
4.1 Operation/control
Step 1
!
Always read the technical data thoroughly. See chapter 6 Technical data
CAUTION
Alfa Laval cannot be held responsible for incorrect operation/control.
Step 2
!
Never touch the pump or the pipelines when pumping hot liquids
or when sterilising.
Danger of burns!
Step 3
!
Never run the pump with both the suction side and the pressure
side blocked. Explosion danger!
=>See the warning label!
Step 4
CAUTION
The shaft seal must not run dry.
CAUTION
Never throttle the inlet side.
Step 5
Flushed shaft seal:
1. Connect the inlet of the flushing liquid correctly.
2. Regulate the water supply correctly.
3. Observe the steam data.
O: Free outlet
I: Inlet
Correct!
Free
out-
let
Tmax =100°C
R1/8”
(BSP) Inlet
Pmax =1bar(water)
Step 6
Control:
Reduce the capacity and the power consumption by means of:
- Throttling the pressure side of the pump.
- Reducing the impeller diameter.
- Reducing the speed of the motor.
12

4Operation
Pay attention to possible faults.
Study the instructions carefully.
4.2 Trouble shooting
NOTE!
Study the maintenance instructions carefully before replacing worn parts. - See section 5.1 General maintenance
Problem Cause/result Remedy
Overloaded motor - Pumping of viscous liquids - Larger motor or smaller impeller
- Pumping of liquids with high density
- Low outlet pressure (counter pressure) - Higher counter pressure (throttling)
- Lamination of precipitates from the
liquid - Frequent cleaning
Cavitation:
- Damage - Low inlet pressure - Increase the inlet pressure
- Pressure reduction (sometimes to
zero) - High liquid temperature - Reduce the liquid temperature
- Increasing of the noise level - Reduce the pressure drop before the
pump
- Reduce speed
Leaking shaft seal - Dry run Replace:
All wearing parts
- Incorrect rubber grade If necessary:
- Change rubber grade
- Abrasive particles in the liquid - Select stationary and rotating seal ring
in silicon carbide/silicon carbide
Leaking O-ring seals Incorrect rubber grade Change rubber grade
13

4Operation
The pump is designed for cleaning in place (CIP). CIP = Cleaning In Place.
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic soda.
HNO3= Nitric acid.
4.3 Recommended cleaning
Step 1
Always handle lye and acid with great care.
Caustic danger!
Always use rubber gloves! Always use protective
goggles!
Step 2
!
Never touch the pump or the pipelines when sterilising.
Danger of burns!
Step 3
Examples of cleaning agents: Use clean water, free from chlorides.
1. 1% by weight NaOH at 70°C (158°F).
1kg(2.2lb) +100 l (26.4 gal) = Cleaning agent.
NaOH water
2.2 l (0.6 gal) +100 l (26.4 gal) = Cleaning agent.
33% NaOH water
2. 0.5% by weight HNO3at 70°C (158°F).
0.7 l (0.2 gal) +100 l (26.4 gal) = Cleaning agent.
53% HNO3water
1. Avoid excessive concentration
of the cleaning agent
⇒Dose gradually!
2. Adjust the cleaning flow to the
process.
Sterilisation of milk/viscous
liquids
⇒Increase the cleaning flow!
Step 4
!
Always rinse well with clean water after using a cleaning agent.
NOTE
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
Always rinse!
Clean water Cleaning agent
14

5 Maintenance
Maintain the pump carefully. Study the instructions carefully and pay special attention to the warnings!
Always keep spare shaft seals and rubber seals in stock.
See separate motor instructions.
Check the pump for smooth operation after service.
5.1 General maintenance
Step 1
!
Always read the technical data thoroughly. (See chaper 6 Technical data)
Always disconnect the power supply when servicing the pump.
NOTE
All scrap must be stored/discharged in accordance with current rules/directives.
Step 2
Never service the pump when it is hot.
Danger of burns!
Step 3
Never service the pump with pump and pipelines under pressure.
CAUTION
Fit the electrical connections correctly if they have been removed
from the motor during service. (see 3.3 Pre-use check)
CAUTION
Pay special attention to the warnings!
Atmospheric pressure
required!
Step 4
Recommended spare parts:
Order service kits from the service kits list
See chapter 7 Parts list and service kits
Ordering spare parts
Contact your local Alfa Laval sales company.
Note:
If the pump is supplied with FEP O-rings, Alfa Laval recommends that the casing O-ring is replaced during maintenance
of the pump.
15

5 Maintenance
Maintain the pump carefully. Study the instructions carefully and pay special attention to the warnings!
Always keep spare shaft seals and rubber seals in stock.
See separate motor instructions.
Check the pump for smooth operation after service.
Shaft seal Rubber seals Motor bearings
Preventive maintenance Replace after 12 months:
(one-shift) Complete shaft seal
Replace when replacing the
shaft seal
Maintenance after leakage
(leakage normally starts slowly)
Replace at the end of the
day: Complete shaft seal
Replace when replacing the
shaft seal
Planned maintenance - Regular inspection for
leakage and smooth
operation
- Keep a record of the pump
- Use the statistics for
inspection planning
Replace after leakage:
Complete shaft seal
Replace when replacing the
shaft seal
Yearly inspection is
recommended
- Replace complete bearing
if worn
- Ensure that the bearing is
axially locked (See motor
instructions)
Lubrication Before fitting
Lubricate the O-rings with
silicone grease or silicone oil
Before fitting
Lubricate with silicone grease
or silicone oil
See section
Pre-use check
CAUTION!
Fit the electrical connections correctly if they have been removed from the motor during service. (See 3.3 Pre-use check).
Pay special attention to warnings!
1. Start and stop the motor momentarily.
2. Ensure that the pump operates smoothly.
16

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
5.2 Dismantling - single shaft seal
Step 1
Remove nuts (8) and yoke (5).
Step 2
Remove pump casing (7) and O-ring (10) from back plate (9), (use a plastic hammer, if necessary).
Step 3
Turn impeller (6) anticlockwise and remove it from pump shaft (26), (use a plastic hammer, if necessary).
Step 4
1. Remove back plate (9).
2. The shaft seal is now accessible.
Step 5
Turn nut (24) clockwise and remove it from stationary seal ring (23).
Step 6
Remove stationary seal ring (23) and seal (25) from back plate (9).
Step 7
1. Remove rotating seal ring (27) and O-ring (29) from pump shaft (26).
2. Remove spring (22) from the rotating seal ring.
Step 8
1. Remove screws (2) and washers (3).
2. Remove adaptor (4).
3. Remove pin (28) and thrower (21).
4. Remove pump shaft (26) from the motor shaft.
17

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
5.3 Dismantling - flushed shaft seal
Step 1
1. Remove nuts (8) and yoke (5).
2. Remove pump casing (7) and O-ring (10) from back plate (9), (use a plastic hammer, if necessary).
3. Turn impeller (6) anticlockwise and remove it from pump shaft (42), (use a plastic hammer, if necessary).
Step 2
Remove back plate (9) together with the complete shaft seal and intermediate flange (44).
Step 3
1. Remove flushing tubes (45)
2. Turn seal housing (35) clockwise and remove it together with fastening ring (43).
3. Remove O-ring (41) from the fastening ring.
Step 4
Remove stationary seal ring (23) and seal (25) from back plate (9).
Step 5
1. Remove screws (39).
2. Remove fastening ring (43) and O-ring (40) from seal housing (35).
3. The shaft seal is now accessible.
Step 6
Remove rotating seal rings (36), O-rings (29), washers (30), spring (37) and spacer (31) from seal housing (35).
Step 7
Remove stationary seal ring (33) and O-ring (32) from seal housing (35).
Step 8
1. Remove screws (2) and washers (3).
2. Remove adaptor (4).
3. Remove pin (34).
4. Remove pump shaft (42) from the motor shaft.
18

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Lubricate the rubber seals before fitting them.
5.4 Assembly - single shaft seal
Step 1
1. Fit thrower (21) on pump shaft (26).
2. Fit the pump shaft on the motor shaft and lock it with pin (28).
3. Fit adaptor (4), washers (3) and screws (2).
4. Lubricate the external surface of the pump shaft.
Step 2
1. Lubricate O-ring (29).
2. Fit the O-ring on pump shaft (26).
CAUTION
Ensure that the driver on the drive ring enters the notch in the rotating seal ring.
Step 3
1. Lubricate the inner surface of rotating seal ring (27).
2. Fit spring (22) on the rotating seal ring.
3. Push the rotating seal ring over O-ring (29) as far as possible against the shoulder.
Step 4
1. Fit seal ring (25) and stationary seal ring (23) in back plate (9)
2. Fit nut (24), turn it anticlockwise and tighten.
Step 5
Fit back plate (9) together with the stationary shaft seal parts on adaptor (4).
Step 6
1. Fit impeller (6) with the rounded part of the hub outwards and turn it clockwise.
2. Check the clearance between back plate (9) and the impeller (0.8-1 mm).
Step 7
1. Lubricate O-ring (10) and fit it on back plate (9).
2. Fit pump casing (7).
Step 8
Fit yoke (5) and nuts (8).
19

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Lubricate the rubber seals before fitting them.
5.5 Assembly - flushed shaft seal
Step 1
1. Fit pump shaft (42) on the motor shaft and lock it with pin (34).
2. Fit adaptor (4), washers (3) and screws (2).
3. Lubricate the external surface of the pump shaft.
Step 2
1. Fit seal (25) and stationary seal ring (23) on back plate (9)
2. Fit O-ring (41) in fastening ring (43).
3. Fit the fastening ring to the back plate, turn it anticlockwise and tighten.
Step 3
1. Push assembly mandrel (46) through the hole in the assembled
back plate.
2. Fit rotating seal rings (36), O-rings (29), washers (30), spring
(37) and spacer (31).
NOTE! Ensure correct position of the joint if using Teflon O-rings.
Assemble the shaft seal in
correct order!
Step 4
1. Fit O-rings (32, 40) and stationary seal ring (33) in seal housing (35).
2. Tighten the seal housing to fastening ring (43) by means of screws (39).
3. Fit intermediate flange (44) on back plate (9).
4. Fit and tighten flushing tubes (45).
Step 5
1. Push mandrel (46) together with the shaft seal parts onto pump shaft (42).
2. Push back plate (9) together with the shaft seal into its correct position.
Step 6
1. Fit impeller (6) with the rounded parts of the hub outwards and turn it clockwise.
2. Check the clearance between back plate (9) and the impeller (0.8-1 mm).
Step 7
1. Lubricate O-ring (10) and fit it on back plate (9).
2. Fit pump casing (7).
Step 8
Fit yoke (5) and nuts (8).
5.6 Assembly - new shaft
Step 1
1. Fit the pump shaft to the motor shaft.
(Hit a mark in the motor shaft with a chisel before the pump shaft is mounted.
This way the shaft can be adjusted with a hammer and not move unintentionally)
2. Fit the adaptor part, back plate and impeller.
3. Adjust shaft position so that there is about 1 mm between the impeller and back plate.
4. Remove impeller, back plate and adapter so only the pump shaft is remaining, in the right position.
5. Drill a hole (ø4 +/- 0.2) through both motor shaft and pump shaft with the pump shaft in the right position.
6. The hole must NOT be drilled in the keyway of the motor.
7. Mount ø4x30 pin using a small hammer.
20