Alfalaval M200 User manual

Alfa Laval M Gear
Gear Pump
BRITISH ENGLISH
3300-0000
Lit. Code 200009584-1-EN-GB Instruction Manual

Published by
Alfa Laval Kolding A/S
Albuen 31
DK-6000 Kolding, Denmark
[phone]
The original instructions are in English
© Alfa Laval AB 2023-06
This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval AB (publ) or any of its affiliates (jointly “Alfa Laval”). No part of this
document may be copied, re-produced or transmitted in any form or by any means, or for any purpose, without Alfa Laval’s prior express written permission. Information and services
provided in this document are made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these
services for any purpose. All rights are reserved.

Contents
1 Declarations of Conformity.................................................................................5
1.1 EU Declaration of Conformity....................................................................................5
1.2 UK Declaration of Conformity....................................................................................6
2 Safety............................................................................................................................... 7
2.1 Safety Instructions and Warnings..............................................................................7
2.2 Warning Signs in Text.............................................................................................. 11
2.3 Requirements of Personnel.....................................................................................12
2.4 Recycling Information..............................................................................................13
3 Introduction.................................................................................................................15
3.1 Principles.................................................................................................................15
4 Installation................................................................................................................... 17
4.1 Unpacking and Handling......................................................................................... 17
5 Operation..................................................................................................................... 19
5.1 Commissioning and Start Up...................................................................................19
5.2 Cleaning.................................................................................................................. 19
6 Maintenance.............................................................................................................. 21
6.1 Disassembly............................................................................................................ 22
6.2 Assembly.................................................................................................................23
6.2.1 Assemble Drive Shaft Assembly................................................................23
6.2.2 Assemble Pump.........................................................................................25
6.3 Troubleshooting.......................................................................................................27
7 Technical Data..........................................................................................................29
7.1 Weights....................................................................................................................29
7.2 Dimensions..............................................................................................................30
8 Spare Parts.................................................................................................................31
8.1 Ordering Spare Parts...............................................................................................31
8.2 Alfa Laval Service....................................................................................................31
9 Parts List and Exploded View........................................................................ 33

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1 Declarations of Conformity
1.1 EU Declaration of Conformity
The Designated Company
Alfa Laval Kolding A/S, Albuen 31, DK-6000 Kolding, Denmark, [phone]
Company name, address and phone number
Hereby declare that
Pump
Designation
M200; M210; M220
Type
Serial number from E10.000 to E1.000.000
Serial number from AAX000000001 to AAX999999999
is in conformity with the following directives with amendments:
• Machinery Directive 2006/42/EC
• RoHS Directive 2011/65/EU and amendments
The person authorised to compile the technical file is the signer of this document.
Global Product Quality Manager Lars Kruse Andersen
Title Name
Kolding, Denmark 2023–06–19
Place Date (YYYY-MM-DD) Signature
DoC Revison_01_062023
200009584-1-EN-GB 5
EN

1.2 UK Declaration of Conformity
The Designated Company
Alfa Laval Kolding A/S, Albuen 31, DK-6000 Kolding, Denmark, [phone]
Company name, address and phone number
Hereby declare that
Pump
Designation
M200; M210; M220
Type
Serial number from E10.000 to E1.000.000
Serial number from AAX000000001 to AAX999999999
is in conformity with the following directives with amendments:
• The Supply of Machinery (Safety) Regulations 2008
• The Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regu-
lations 2012
Signed on behalf of: Alfa Laval Kolding A/S
Global Product Quality Manager Lars Kruse Andersen
Title Name
Kolding, Denmark 2023–06–19
Place Date (YYYY-MM-DD) Signature
DoC Revison_01_062023
200009584-1-EN-GB6
1 Declarations of ConformityEN

2 Safety
Read this first
This manual is designed for operators and service engineers working with the supplied
Alfa Laval product.
Operators must read and understand the “Safety, Installation and Operating Instruc-
tions” of the respective product before carrying out any work or before you put the sup-
plied product into service!
Not following the instructions can result in serious accidents.
This documentation describes the authorized way to use the supplied product.
Alfa Laval will take no responsibility for injury or damage if the equipment is used in any
other way.
This Instruction manual is designed to provide the user with the information to perform
tasks safely for all phases in the lifetime of the supplied product.
The user shall always read the safety section first. Hereafter the user can skip to the rele-
vant section for the task to be carried out or for the information needed.
Always read the technical data thoroughly (see Technical Data on page 29).
This is the complete manual for the supplied product.
2.1 Safety Instructions and Warnings
Safety Signs
Use eye protection - safety glasses.
Use protective hand wear - safety gloves.
Wear protective equipment - safety helmet.
Use ear protection in noisy environments - noise protector.
Wear protective equipment - safety shoes.
Corrosive substance.
Hot surface and burning danger.
Cutting danger
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EN

Safety Signs
Dangerous electrical voltage
Transportation with forklift truck or other industrial vehicles if heavy.
General Safety Precautions
Installation
If the local safety regulations prescribe that the installation has to be inspected and ap-
proved by responsible authorities before the pump is put into service, consult with such
authorities before installing the equipment and have the projected installation approved by
them.
Never start in the wrong direction of rotation with liquid in the pump.
Never put your hands or fingers inside the port connections or anywhere close to rotating
shafts.
Always have the pump electrically connected by authorized personnel. (See the motor in-
struction supplied with the drive unit)
Alfa Laval recommends the supply disconnecting device shall be in accordance with EN
60204-1.
Operation
Never stand on the pump or pipelines.
Never run the pump with either the suction side or the pressure side blocked.
Never put your hands or fingers inside the port connections or anywhere close to rotating
parts.
Never run the pump unless fully assembled and all guards are securely fitted, i.e. pump
head must not be removed from gearcase. !
Always ensure any guards are securely fitting and in good condition.
Never touch the pump or the pipelines when pumping hot liquids or when sterilising.
In certain operating conditions external surfaces of the pump and/or ancillary equipment
may exceed 80° C. As such users should avoid touching the pump and/or ancillary equip-
ment during operation taking precautions if it is unavoidable to do so.
Only handle toxic and acidic liquids in accordance with the manufacturers instructions and
recommendations.
200009584-1-EN-GB8
2 SafetyEN

Maintenance
Always ensure adequate Personal Protective Equipment (PPE) is worn during any main-
tenance activities.
Never service the pump when it is hot.
Never service the pump when the pump and pipelines are pressurised.
Never put your hands or fingers inside the port connections or anywhere close to rotating
parts.
Always comply with any local health and safety regulations when installing and operating
the pump.
Any hazardous and/or hot, drained or leaked, liquid shall be disposed in compliance with
any local health and safety regulations. If requested at the time of quotation, the equip-
ment can be supplied with a means of safe containment of any hazardous and/or hot,
drained or leaked liquid (Drip Pan).
Always ensure the power supply is disconnected (in an off position) and is locked out to
prevent accidental operation. Please refer to any motor/geared motor and coupling operat-
ing manuals supplied with the unit for maintenance instructions.
Always ensure pump and ancillary equipment has been allowed to cool before touching.
Transportation and Lifting
Never lift or elevate in any way other than 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 it’s upright position
Always ensure that the unit is securely fixed during transportation
Always use original packaging or similar during transportation
Always use a suitable transport device i.e. forklift truck or pallet lifter
Storage
Ideally, as a guide Alfa Laval recommend:
• Store supplied product as supplied in original packaging
• Port opening should be protected against any ingress
• Bare steel (not stainless) should be lightly oiled/greased
• Store in a clean, dry place without direct sunlight or UV light
• Temperature range -5 to 40° C
• Relative humidity less than 60%
• No exposure to corrosive substances (also air contained)
Noise
Under certain operating conditions pumps and/or drives and/or the systems within which
they are installed can produce sound pressure levels in excess of 80 dB[A].
When necessary, protection against noise should be taken.
200009584-1-EN-GB 9
Safety 2 EN

Safety check
A visual inspection of any protective device (shield, guard, cover or other) on the supplied
product shall be carried out at least every 12 months. If the protective device is lost or
damaged, especially when this leads to deterioration of safety performance, it shall be re-
placed. The fixing of the protective device should only be replaced with fixings of the same
or an equivalent type.
Inspection acceptance criteria:
• It should not be possible to reach moving parts originally protected by a protective de-
vice
• The protective device must be securely mounted
• Ensure that screws for the protective device are securely tightened
Procedure in case of non-acceptance:
• Fix and/or replace the protective device
How to contact Alfa Laval
Contact details for all countries are continually updated on our website.
Please visit www.alfalaval.com to access the information directly.
200009584-1-EN-GB
10
2 SafetyEN

2.2 Warning Signs in Text
Pay attention to the safety instructions in this manual.
Below are definitions of the four grades of warning signs used in the text where there is a risk for
injury to personnel or product damage.
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 damage
on the product.
NOTE
Indicates important information to simplify or clarify procedures.
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Safety 2 EN

2.3 Requirements of Personnel
Operators
The operators shall read and understand the instruction manual for the supplied product.
Maintenance personnel
The maintenance personnel shall read and understand the instruction manual. The maintenance
personnel or technicians shall be skilled within the field required to carry out the maintenance work
safely.
Trainees
Trainees can perform tasks under the supervision of an experienced employee.
People in general
The public shall not have access to the supplied product.
In some cases special skilled personnel may need to be hired, like electricians and others. In some of
these cases the personnel has to be certified according to local regulations with experience of similar
types of work.
How to contact Alfa Laval
Contact details for all countries are continually updated on our website.
Please visit www.alfalaval.com to access the information directly.
200009584-1-EN-GB
12
2 SafetyEN

2.4 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.
• Oil and all non-metal wearing parts must be disposed of in accordance with local regulations
• Rubber and plastics should be burnt at a licensed waste incineration plant. If not available they
should be disposed in accordance with local regulations
• Bearings and other metal parts should be sent to a licensed handler for material recycling
• Seal rings and friction linings should be disposed to a licensed land fill site. Check your local
regulations
• All metal parts should be sent for material recycling
• Worn out or defected electronic parts should be sent to a licensed handler for material recycling
Scrapping
• At end of use, the equipment must be recycled in accordance with the relevant local regulations.
Besides the equipment itself, any hazardous residues from the process liquid must be considered
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.
200009584-1-EN-GB 13
Safety 2 EN

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3 Introduction
The Alfa Laval M Gear is an external gear pump that efficiently transfers low-
volume fluids for filling applications. Precision alignment, easy cleaning and
simple maintenance make the stainless-steel M Gear pump a solid choice for
dosing, sampling and filling machines. This proven rotary positive
displacement pump easily adapts to OEM filling machines.
3.1 Principles
The M Gear pump supplied is a positive displacement gear pump which may
be supplied with or without a drive unit. The drawing below indicates the main
components of the pump.
3300-0001
A
B
F
E
G
H
C
D
Item Description Item Description
A Back Plate E Front Bushing
B Drive Shaft Assembly F Body
C Rear Bush (Aux. shaft) G Front Cover
D Auxiliary shaft H Hand Nut
Principle of Operation
The M Gear pump has two counter gears and can operate in both flow
directions by reversing the drive rotation.
3300-0002
Top shaft drive Bottom shaft drive
As the gear rotate within the body the volume at the inlet increases and the
product is drawn in to the pump. It is then transported within the space
between the gears and the periphery of the body to the discharge side where
the volume between the gears is reduced and the product is discharged.
200009584-1-EN-GB 15
EN

Pump Limits of Application and Use
This pump has been designed for pumping a range of clean, semi-solid
viscous products for transfer, dosing and sampling in the food, chemical and
associates industries.
Pressures up to 7 bar, speeds up to 1360 rpm and temperatures up to 60°C
can be obtained on this pump range depending on model. These conditions
cannot always be accommodated simultaneously. The model type/size will be
shown on the nameplate positioned on the pump.
If the user has not specified the pumping application or needs to change it, it is
important to confirm that the materials of construction and product seals are
compatible with the pumped liquid.
For specific guidelines contact your supplier quoting pump serial number,
system and duty details. (e.g. media, pressures, flowrate, pumping
temperatures etc).
Duty conditions
The pump should only be used for the duty for which it has been specified.
The operating pressure, speed and temperature limits have been selected at
the time of order and MUST NOT be exceeded. These details are stated on
the original documentation and if not available may be obtained from your
supplier quoting pump serial number
Utility requirements
Electrical supply: This pump may be supplied bareshaft or coupled to an
electric motor. See motor nameplate for electrical supply requirements.
200009584-1-EN-GB
16
3 IntroductionEN

4 Installation
4.1 Unpacking and Handling
Receipt and unpacking
On receipt always:
• Check the delivery note against good received
• If motorised check that the drive instructions are available
• Inspect packing for signs of damage in transit
• Carefully remove packing away from the pump
• Clean away packing form the pump port connections
• Ensure any manuals are taken out of the packing before discarding
• Inspect the pump unit for any signs of damage
• Report any damage immediately to the carrier
Handling
WARNING
Always ensure any personnel undertaking lifting operations have the suitable
experience and training to do so safely.
Ensure any lifting equipment used is in good condition and has been suitably
tested, using lifting lugs when applied.
Ensure any lifting equipment used is rated for and used within the load limits.
Refer to the pump weights guide.
Always ensure that the lifting points are in line with the centre of gravity and
adjust lifting point if necessary.
Always keep an eye on the load and stay clear during the lifting operation.
The diagrams below show examples of how the equipment should be lifted,
however the user is to ensure this can be done safely with the equipment at
hand:
Motorised
3300-0004
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EN

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5 Operation
5.1 Commissioning and Start Up
Pump Lubrication
The M Gear pump range does not require any external lubrication.
Pre-Start Up Checks
• Check the pipework systems has been flushed to remove debris such as
welding slag or other hard solids
• Check all obstructions have been removed from the pipework and pump
• Check pump connections and pipework are tight and leak-free
• Check pump lubrication levels in both pump and drive unit (if applicable)
• Check that any safety guards or devices are in place and in good condition
• Check that the inlet and outlet valves are open
• Start the pump briefly to ensure correct direction of rotation and presence
of fluid.
• Start pump and check the operating conditions are within the operating
limits of the pump.
In the event of any unusual noise, vibration or leakage the unit should be shut
down immediately and the problem investigate and rectified before restarting.
5.2 Cleaning
The M Gear pump has been designed for Clean Out of Place (COP) manual
cleaning only.
200009584-1-EN-GB 19
EN

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