Alfalaval MR-300 User manual

ESE02051-EN62022-10
Originalmanual
InstructionManual
MR-300Liquid-RingPump

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
1.DeclarationsofConformity.................................................................4
2.Safety..........................................................................................6
2.1.Importantinformation.............................................................................6
2.2.Warningsigns.....................................................................................6
2.3.Safetyprecautions................................................................................
3.Installation....................................................................................8
3.1.Unpacking/delivery...............................................................................8
3.2.Installation/pre-usecheck........................................................................9
3.3.Recyclinginformation.............................................................................11
4.Operation.....................................................................................12
4.1.Operation/control.................................................................................12
4.2.Troubleshooting..................................................................................13
4.3.Recommendedcleaning.........................................................................14
5.Maintenance..................................................................................15
5.1.Generalmaintenance.............................................................................15
5.2.Dismantlingofpump/removingtheshaftseal(1-4*)...........................................1
5.3.Assemblyofpump/fittingofshaftseal(5-8*)...................................................18
5.4.Adjustmentofimpellerposition..................................................................19
6.Technicaldata................................................................................20
6.1.Technicaldata.....................................................................................20
6.2.Torquespecifications.............................................................................21
6.3.Weight(kg)........................................................................................21
6.4.Noiseemission....................................................................................22
7.Partslistandservicekits...................................................................23
.1.Drawings...........................................................................................23
.2.MR-Wetend.....................................................................................24
.3.MR-Motordependentparts....................................................................26
.4.MR-Shaftseal...................................................................................28
3

1DeclarationsofConformity
EU EU
EUDeclaration Declaration Declarationof of ofConformity Conformity Conformity
TheDesignatedCompany
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companyname,addressandphonenumber
Herebydeclarethat
Pump
Designation
MR-300
Type
Serialnumberfrom10.000to1.000.000
isinconformitywiththefollowingdirectiveswithamendments:
-MachineryDirective2006/42/EC
-RoHSEUDirective2011/65/EUandamendments
Thepersonauthorisedtocompilethetechnicalfileisthesignerofthisdocument.
GlobalProductQualityManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
ThisDeclarationofConformityreplacesDeclarationofConformitydated2016-02-01
4

1DeclarationsofConformity
UK UK
UKDeclaration Declaration Declarationof of ofConformity Conformity Conformity
TheDesignatedCompany
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companyname,addressandphonenumber
Herebydeclarethat
Pump
Designation
MR-300
Type
Serialnumberfrom10.000to1.000.000
isinconformitywiththefollowingdirectiveswithamendments:
-TheSupplyofMachinery(Safety)Regulations2008
-TheRestrictionoftheUseofCertainHazardousSubstancesinElectricalandElectronicEquipmentRegulations2012
Signedonbehalfof:AlfaLavalKoldingA/S
GlobalProductQualityManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
DoCRevison_01_102022
5

2Safety
Unsafepracticesandotherimportantinformationareemphasisedinthismanual.
Warningsareemphasisedbymeansofspecialsigns.Allwarningsinthemanualaresummarisedonthispage.
Payspecialattentiontotheinstructionsbelowsothatseverepersonalinjuryordamagetothepumpareavoided.
2.1Importantinformation
Always Always
Alwaysr r read ead eadthe the themanual manual manualbefor befor before e eusing using usingthe the thepump! pump! pump!
W W
WARNING ARNING ARNING
Indicatesthatspecialproceduresmustbefollowedtoavoidseriouspersonalinjury.
CAUTION CAUTION
CAUTION
Indicatesthatspecialproceduresmustbefollowedtoavoiddamagetothepump.
NOTE NOTE
NOTE
Indicatesimportantinformationtosimplifyorclarifyprocedures.
2.2Warningsigns
Generalwarning:
Dangerouselectricalvoltage:
Causticagents:
6

2Safety
Unsafepracticesandotherimportantinformationareemphasisedinthismanual.
Warningsareemphasisedbymeansofspecialsigns.Allwarningsinthemanualaresummarisedonthispage.
Payspecialattentiontotheinstructionsbelowsothatseverepersonalinjuryordamagetothepumpareavoided.
2.3Safetyprecautions
Installation: Installation:
Installation:
Always Always
Alwaysreadthetechnicaldatathoroughly.(Seechapter6Technicaldata)
Always Always
Alwaysusealiftingcranewhenhandlingthepump.
Never Never
Nevertestthedirectionofrotationwithliquidinthepump.
Always Always
Alwayshavethepumpelectricallyconnectedbyauthorisedpersonnel.(Seethemotorinstruction)
Always Always
Alwaysdisconnectthepowersupplywhenservicingthepump.
Operation: Operation:
Operation:
Always Always
Alwaysreadthetechnicaldatathoroughly.(Seechapter6Technicaldata)
Never Never
Nevertouchthepumporthepipelineswhenpumpinghotliquidsorwhensterilising.
Never Never
Neverrunthepumpwithboththesuctionsideandthepressuresideblocked.
Never Never
Neverrunthepumpwhenpartiallyinstalledornotcompletelyassembled.
Necessary Necessary
Necessaryprecautionsmustbetakenifleakageoccursasthiscanleadtohazardoussituations.
Always Always
Alwayshandlelyeandacidwithgreatcare.
Never Never
NeverusethepumpforproductsnotmentionedintheAlfaLavalpumpselectionprogram.
TheAlfaLavalpumpselectionprogramcanbeacquiredfromyourlocalAlfaLavalsalescompany.
Maintenance: Maintenance:
Maintenance:
Always Always
Alwaysreadthetechnicaldatathoroughly.(Seechapter6Technicaldata)
Never Never
Neverservicethepumpwhenitishot.
Never Never
Neverservicethepumpifpressurised.
Always Always
AlwaysuseAlfaLavalgenuinespareparts.
Always Always
Alwaysdisconnectthepowersupplywhenservicingthepump.
T T
Transportation: ransportation: ransportation:
T T
Transportation ransportation ransportationof of ofthe the thepump pump pumpor or orthe the thepump pump pumpunit: unit: unit:
Never Never
Neverliftorelevateinanywayotherthanasdescribedinthismanual
Always Always
Alwaysdrainthepumpheadandaccessoriesofanyliquid
Always Always
Alwaysensurethatnoleakageoflubricantscanoccur
Always Always
Alwaystransportthepumpinitsuprightposition
Always Always
Alwaysensurethattheunitissecurelyfixedduringtransportation
Always Always
Alwaysuseoriginalpackagingorsimilarduringtransportation
7

3Installation
3.1Unpacking/delivery
Step Step
Step1 1 1
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrectunpacking.
Inspectthepumpforvisibletransportdamage.
Check Check
Checkthe the thedelivery delivery deliveryfor: for: for:
1.Completepump.
2.Deliverynote.
3.Motorinstructions.
Step Step
Step2 2 2
Cleantheinletandtheoutlettoremovepossiblepackingmaterials.
Step Step
Step3 3 3
Avoiddamagingtheinletandtheoutlet.
Step Step
Step4 4 4
Alwaysremovetheshroud,iffitted,beforeliftingthepump.
8

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!
Thedirectionofrotationoftheimpellercanbecheckedbyobservingthedirectionofrotationofthemotorfan.
Seetheindicationlabelonthepump.
3.2Installation/pre-usecheck
Step Step
Step1 1 1
Always Always
Alwaysreadthetechnicaldatacarefully.
Seechaper6Technicaldata
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrectinstallation.
Never Never
Neverstickyourfingersoranytoolthroughtheadaptororthe
drainholeinthepumpcasingwhenthepumpisrunning.
W W
WARNING: ARNING: ARNING:
AlfaLavalrecommendstheinstallationofalockable
repairbreaker.Iftherepairbreakeristobeusedas
anemergencystop,thecoloursoftherepairbreaker
mustberedandyellow.
CAUTION CAUTION
CAUTION
Thepumpdoesnotpreventbackflowwhen
intentionallyorunintentionallystopped.Ifbackflow
cancauseanyhazardoussituations,precautions
mustbetakene.g.acheckvalvemustbeinstalledin
thesystemtopreventthisfromhappening.
NOTE!
Incaseofshaftsealleakage,themediawilldripfrom
theslotinthebottomoftheadaptor.Incaseofshaft
sealleakage,AlfaLavalrecommendsplacingadrip
trayunderneaththeslotforcollectingtheleakage.
Step Step
Step2 2 2
Ensureatleast0.5mclearancearoundthepump.
Step Step
Step3 3 3
Ensurethattheflowdirectioniscorrect.Inlet
Step Step
Step4 4 4
1.Ensurethatthepipelinesarecorrectlyrouted.
2.Ensurethatconnectionsaretight.
Few
bends!
Correct!
Remem-
berseal
rings!A
A=Min.1m
Step Step
Step5 5 5
Avoidstressestothepump.
Payspecialattentionto:
-Vibrations.
-Thermalexpansionofthetubes.
-Excessivewelding.
-Overloadingofthepipelines.
Riskofdamage!
9

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!
Thedirectionofrotationoftheimpellercanbecheckedbyobservingthedirectionofrotationofthemotorfan.
Seetheindicationlabelonthepump.
Step Step
Step6 6 6
Never Never
Nevertestthedirectionofrotationwithliquidinthepump.
Pr Pr
Pre e e- - -use use usecheck: check: check:
1.Startandstopthemotormomentarily.
2.Ensurethatthedirectionofrotationofthemotorisclockwise
asviewedfromthebackofthemotor.
10

3Installation
3.3Recyclinginformation
• •
•Unpacking Unpacking Unpacking
-Packingmaterialconsistsofwood,plastics,cardboardboxesandinsomecasesmetalstraps.
-Woodandcardboardboxescanbereused,recycledorusedforenergyrecovery.
-Plasticsshouldberecycledorburntatalicensedwasteincinerationplant.
-Metalstrapsshouldbesentformaterialrecycling.
• •
•Maintenance Maintenance Maintenance
-Duringmaintenance,oilandwearpartsinthemachinearereplaced.
-Allmetalpartsshouldbesentformaterialrecycling.
-Wornoutordefectiveelectronicpartsshouldbesenttoalicensedhandlerformaterialrecycling.
-Oilandallnon-metalwearpartsmustbetakencareofinagreementwithlocalregulations.
• •
•Scrapping Scrapping Scrapping
-Attheendofuse,theequipmentshallberecycledaccordingtotherelevant,localregulations.Besidestheequipmentitself,
anyhazardousresiduesfromtheprocessliquidmustbeconsideredanddealtwithinapropermanner.Whenindoubt,orin
theabsenceoflocalregulations,pleasecontactyourlocalAlfaLavalsalescompany.
11

4Operation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
4.1Operation/control
Step Step
Step1 1 1
Always Always
Alwaysreadthetechnicaldatacarefully.
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrect
operation/control.
Step Step
Step2 2 2
Never Never
Nevertouchthepumporthepipelineswhenpumpinghotliquids
orwhensterilising.
Danger Danger
Dangerof of ofbur bur burns! ns! ns!
Step Step
Step3 3 3
Neverrunthepumpwithboththesuctionsideandthepressure
sideblocked.
Danger Danger
Dangerof of ofexplosion! explosion! explosion!
Step Step
Step4 4 4
Never Never
Neverstickyourfingersoranytoolthroughtheadaptororthe
drainholeinthepumpcasingwhenthepumpisrunning.
Rotating Rotating
Rotatingparts! parts! parts!
Step Step
Step5 5 5
CAUTION CAUTION
CAUTION
Theshaftsealmustnotrundry.
CAUTION CAUTION
CAUTION
Never Never
Neverthrottletheinletside.
Step Step
Step6 6 6
Contr Contr
Control: ol: ol:
Reducethecapacitybymeansof:
-Throttlingthepressuresideofthepump.
-Speedcontrolofthemotor.
12

4Operation
Payattentiontopossiblefaults.
Studytheinstructionscarefully.
4.2Troubleshooting
NOTE! NOTE!
NOTE!
Studythemaintenanceinstructionscarefullybeforereplacingwornparts.
Pr Pr
Problem oblem oblemCause/r Cause/r
Cause/result esult esultRemedy Remedy
Remedy
Overloadmotor-Pumpingofviscousliquid-18.5kWmotorif15kWisfitted
-Pumpingofhighdensityliquids-Increasecapacity
Leakingshaftseal-DryrunReplace: Replace:
Replace:
Allwearingparts
-Incorrectrubbergrade-Selectadifferentrubbergrade
LeakingO-ringsealsIncorrectrubbergradeChangerubbergrade
13

4Operation
Thepumpisdesignedforcleaninginplace(CIP).CIP=CleaningInPlace.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
NaOH=CausticSoda.
HNO3=Nitricacid.
4.3Recommendedcleaning
Step Step
Step1 1 1
Always Always
Alwayshandlelyeandacidwithgreatcare.
Caustic Caustic
Causticdanger! danger! danger!
Alwaysuserubbergloves!Alwaysuseprotective
goggles!
Step Step
Step2 2 2
Never Never
Nevertouchthepumporthepipelineswhenpumpinghotliquids
orwhensterilising.
Danger Danger
Dangerof of ofbur bur burns! ns! ns!
Step Step
Step3 3 3
Examples Examples
Examplesof of ofcleaning cleaning cleaningagents: agents: agents:Usecleanwater,freefromchlorides.
1.1%byweightNaOHat0°C(158°F).
1kg(2.2lb)+100l(26.4gal)=Cleaningagent.
NaOHwater
2.2l(0.6gal)+100l(26.4gal)=Cleaningagent.
33%NaOHwater
2.0.5%byweightHNO3at0°C(158°F).
0.l(0.2gal)+100l(26.4gal)=Cleaningagent.
53%HNO3water
1.Avoidexcessiveconcentration
ofthecleaningagent
⇒Dosegradually!
2.Adjustthecleaningflowtothe
process.
Sterilisationofmilk/viscous
liquids
⇒Increasethecleaningflow!
Step Step
Step4 4 4
Always Always
Alwaysrinsewellwithcleanwaterafterusingacleaningagent.
NOTE NOTE
NOTE
Thecleaningagentsmustbestored/disposedofinaccordance
withcurrentregulations/directives.
Always Always
Alwaysrinse! rinse! rinse!
CleanwaterCleaningagent
14

5Maintenance
Maintainthepumpcarefully.Studytheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayskeepspareshaft
sealsandrubbersealsinstock.Seeseparatemotorinstructions.
5.1Generalmaintenance
Step Step
Step1 1 1
Always Always
Alwaysreadthetechnicaldatacarefully.
Always Always
Alwaysdisconnectthepowersupplywhenservicingthepump.
Always Always
Alwaysdisconnectthepowersupplywhencheckingtheimpeller
position.
NOTE NOTE
NOTE
Allscrapmustbestored/dischargedinaccordance
withcurrentrules/directives.
Step Step
Step2 2 2
Never Never
Neverservicethepumpwhenitishot.
Thepumpandthepipelinesmustnever never
neverbepressurisedwhenthe
pumpisserviced.Danger Danger
Dangerof of ofbur bur burns! ns! ns!
Step Step
Step3 3 3
CAUTION CAUTION
CAUTION
Always Always
Alwaysensurethattheimpellerrotatessmoothlyafterservice.
1.Ensurethatimpeller(11)doesnotcomeintocontactwith
pumpcasing(9a)orcasingcover(10a).
2.Adjusttheimpellerpositionifnecessary(seepage1).
Step Step
Step4 4 4
CAUTION CAUTION
CAUTION
Fittheelectricalconnectionscorrectlyiftheyhavebeenremovedfromthemotorduringservice.
Pay Pay
Payspecial special specialattention attention attentionto to tothe the thewar war warnings! nings! nings!
Or Or
Ordering dering deringspar spar spare e eparts parts parts
ContactyourlocalAlfaLavalsalescompany.
Recommended Recommended
Recommendedspar spar spare e eparts: parts: parts:
OrderServicekitsfromtheServicekitslist(seechapterPartslistandservicekits).
15

5Maintenance
Maintainthepumpcarefully.Studytheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayskeepspareshaft
sealsandrubbersealsinstock.Seeseparatemotorinstructions.
Shaft Shaft
Shaftseals seals sealsRubber Rubber
Rubberseals seals sealsMotor Motor
Motorbearings bearings bearings
PreventivemaintenanceReplace Replace
Replaceafter after after12 12 12months months months
(one-shift)
Completeshaftseal
Replacewhenreplacingthe
shaftseal
Maintenanceafterleakage
(leakagenormallystartsslowly)
Replace Replace
Replaceat at atthe the theend end endof of ofthe the the
day: day:
day:
Completeshaftseal
Replacewhenreplacingthe
shaftseal
Plannedmaintenance-Regularinspectionfor
leakageandsmooth
operation
-Keeparecordofthepump
-Usethestatisticsfor
inspectionplanning
Replace Replace
Replaceafter after afterleakage: leakage: leakage:
Completeshaftseal
Replacewhenreplacingthe
shaftseal
Yearlyinspectionis
recommended
-Replacecompletebearing
ifworn
-Ensurethatthebearingis
axiallylocked(Seemotor
instructions)
LubricationBefor Befor
Before e efitting fitting fitting
LubricatetheO-ringswith
siliconegreaseorsiliconeoil
Befor Befor
Before e efitting fitting fitting
Siliconegreaseorsiliconeoil
None None
None
Thebearingsarepermanently
lubricated
16

5Maintenance
Studytheinstructionscarefully.Theitemsrefertothepartslistandservicekitssection.Handlescrapcorrectly.
5.2Dismantlingofpump/removingtheshaftseal(1-4*)
Step Step
Step1 1 1
-
Removecapnuts(14),washers(15a)andcasingcover(10a)
Step Step
Step2 2 2
-
1.Removeimpellerscrew(33),washer(32)andO-ring(34),
(counterholdimpeller(11),withthetoolsupplied).
2.Removetheimpeller.
NOTE!
Ensurethatshims(31)remainintheimpeller.
Step Step
Step3 3 3
-
1.Removerotatingsealring(28)fromimpeller(11)byturningit
clockwiseandpullingitsimultaneously.
2.RemoveO-ring(30)washer(16)andspring(24)fromthe
rotatingsealring.
Step Step
Step4 4 4
-
1.Removestationarysealring(29)frompumpcasing(9a)by
hookingthetoolsuppliedtotherearedgeofthesealringand
pullingitout.
2.RemoveO-ring(2)fromthestationarysealring.
Step Step
Step5 5 5
RemoveO-ring(8)frompumpcasing(9a).
Step Step
Step6 6 6
Removeshroud().
Step Step
Step
1.Removescrews(52)andwashers(53).
2.Removepumpcasing(9a).
Step Step
Step8 8 8
1.Removethrower(21)fromthemotorshaft.
17

5Maintenance
Studytheinstructionscarefully.Theitemsrefertothepartslistandservicekitssection.Lubricatetherubbersealsbefore
fittingthem.
5.3Assemblyofpump/ttingofshaftseal(5-8*)
Step Step
Step1 1 1
NOTE!
Theimpellerpositionmayhavetobeadjustedif:
-Themotorhasbeenreplaced.
-Shims(31)aremisssinginimpeller(11).
(Forimpelleradjustment,seepage18).
Step Step
Step2 2 2
1.Fitthrower(21)onthemotorshaft.
2.Fitpumpcasing(9a)onthemotor.
3.Fitwashers(53)andscrews(52).
Step Step
Step3 3 3
1.Fitshrouds().
Step Step
Step4 4 4
1.FitO-ring(8)onpumpcasing(9a).
Step Step
Step5 5 5
-
1.LubricateO-ring(2)andfititonstationarysealring(29).
2.Fitthestationarysealringinpumpcasing(9a).
Step Step
Step6 6 6
-
1.LubricateO-ring(30).
2.FittheO-ring,washer(16)andspring(24)inrotatingsealring
(28).
3.Fittherotatingsealringbyturningitclockwiseandpressing
itsimultaneously.
Step Step
Step
-
1.Checkthatshims(31)arepositionedcorrectlyinimpeller(11).
2.Fittheimpeller.
3.FitO-ring(34)onimpellerscrewhead(33).
4.Fitwasher(32)andtheimpellerscrew(tightenfirmlywhile
counterholdingtheimpellerwiththetoolsupplied).
5.Checkthattheclearancebetweentheimpellerandpump
casing(9a)is0.3-0.4mm.
Step Step
Step8 8 8
-
1.Fitcasingcover(10a),washers(15a)andcapnuts(14).
2.Tightenthecapnutsfirmly.
3.Ensurethatimpeller(11)rotatessmoothly(seepage8).
Pay Pay
Payspecial special specialattention attention attentionto to tothe the thewar war warnings! nings! nings!
18

5Maintenance
Studytheinstructionscarefully.Theitemsrefertothepartslistandservicekitssection.
5.4Adjustmentofimpellerposition
Step Step
Step1 1 1
NOTE!
-Adjusttheimpellerpositionwithonly only
onlythepumpcasing,the
throwerandtheimpellerfittedonthemotor.
-Fitallotherpartsaftertheadjustment.
Step Step
Step2 2 2
1.Fitthrower(21)onthemotorshaft.
2.Fitpumpcasing(9a)onthemotor.
3.Fitwashers(53)andscrews(52).
Step Step
Step3 3 3
Placesomeshims(31)inimpeller(11).
Step Step
Step4 4 4
1.Fitimpeller(11)onthemotorshaft.
2.Fitimpellerscrew(33)andtightenfirmly.
Step Step
Step5 5 5
Adjusttheimpellerpositionbyaddingorremovingshims(31)until
theclearancebetweenimpeller(11)andpumpcasing(9a)is0.3
-0.4mm.
Step Step
Step6 6 6
CAUTION!
Ensurethatthecorrectnumberofshims(31)arefitted.
Toofewortoomanyshimscausetheimpellertocomeintocontact
withthepumpcasingorthecasingcoveranddamagethem.
Theefficiencyofthepumpmayalsobeaffected.
19

6Technicaldata
Itisimportanttoobservethetechnicaldataduringinstallation,operationandmaintenance.
Informpersonnelaboutthetechnicaldata.
6.1Technicaldata
MRisaliquid-ringpumpspeciallydesignedforpumpingliquidscontainingairorgas.Thepumpisforuseinfood,chemical,
pharmaceuticalandsimilarindustries.ThepumpismainlyusedfortheCIP-returnapplication.Thisinstructionmanualispart
ofthedelivery.Readtheinstructionscarefully.
Data
Max.inletpressure400kPa(4bar)
Temperaturerange-10oCto+140oC(EPDM)
Max.speed1800rpm
Materials
ProductwettedsteelpartsAISI316L
OthersteelpartsStainlesssteel
ProductwettedsealsEPDM(standard)
AlternativesealsNitrile(NBR)andflourinatedrubber(FPM)
FinishStandardblasted
Shaftseal
SealtypeMechanicalsingleseal
Material,stationarysealringCarbon
Material,rotatingsealringAcidresistantsteel,duplexgrade
Material,O-ringsEPDM(standard)
Alternativematerial,O-ringsNitrile(NBR)andflourinatedrubber(FPM)
Motor
Standardfoot-flangedmotoraccordingtoIECmetricstandard
4pol=1500/1800rpm.at50/60Hz
IP55(withdrainholeswithlabyrinthplug),insulationclassF
Motorsizes(kW),50Hz15,18.5
Motorsizes(kW),60Hz1,21
Tighteningtorques:Seeaddendum
Noise:Seeaddendum
20