Alfalaval SolidC Series User manual

Instruction Manual
SolidC Pump
ESE00797-EN3 2010-02
Original manual

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 ..................................................................................... 9
3.4. Recycling information ............................................................................. 9
4. Operation ............................................................................................... 10
4.1. Operation/Control ................................................................................. 10
4.2. Fault finding ....................................................................................... 12
4.3. Recommended cleaning ......................................................................... 13
5. Maintenance ........................................................................................... 14
5.1. General maintenance ............................................................................. 14
5.2. Dismantling of pump/shaft seals ................................................................ 16
5.3. Assembly of pump/single shaft seal ............................................................ 18
5.4. Assembly of pump/flushed shaft seal ........................................................... 20
5.5. Adjustment of shaft ............................................................................... 22
6. Technical data ......................................................................................... 23
6.1. Technical data ..................................................................................... 23
7. Parts list and Service Kits ........................................................................... 25
7.1. Drawing ............................................................................................ 25
7.2. SolidC-1 ........................................................................................... 26
7.3. SolidC-2 ........................................................................................... 28
7.4. SolidC-3 ........................................................................................... 30
7.5. SolidC-4 ........................................................................................... 32
7.6. SolidC 1-4, Shaft Seal ............................................................................ 34
3

1 EC Declaration of Conformity
The designated company
Alfa Laval
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Pump SolidC
Denomination Type Year
is in conformity with the following directives with amendments:
- Low Voltage Directive 2006/95/EC
- EMC Directive 2004/108/EC
- Machinery Directive 2006/42/EC
The technical construction file is retained at the above address
Manager, Product center Fluid Handling Bjarne Søndergaard
Title Name
Alfa Laval Kolding
Company Signature
Designation
4

2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized 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 severe 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

2Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
Always read the manual before using the pump!
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.
Never start in the wrong direction of rotation with liquid in the pump.
Always have the pump electrically connected by authorized 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
Necessary precautions must be taken if leakage occurs as this can lead to hazardous situations
Always handle lye and acid with great care.
Maintenance:
Always read the technical data thoroughly. (See chapter 6 Technical data)
Never service the pump when it is hot.
The pump and the pipelines must never be pressurised when the pump is serviced.
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 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
6

3 Installation
The instruction manual is part of the delivery. Study the instructions carefully.
The standard delivery does not include the test certificate. This can be supplied on request.
The large pump sizes are very heavy. Alfa Laval therefore recommends the use of a lifting crane when handling the pump.
3.1 Unpacking/Delivery
Step 1
Always use a lifting crane when handling the pump (See chapter
6 Technical data).
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for
1. Complete pump.
2. Delivery note.
3. Motor instructions.
4. Test certificate, IF ORDERED!I
Step 2
Remove possible packing materials from the inlet and the outlet,
and remove the plastic film wrapped around the pump.
Avoid damaging the inlet and the outlet.
Avoid damaging the connections for flushing liquid, if supplied.
TD 241-003/1
Step 3
Inspect the pump for visible transport damages.
TD 241-003/2
Step 4
Always remove the shroud, if fitted, before lifting the pump.
TD 241-004/1
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, page 9
The large pump sizes are very heavy. Alfa Laval therefore recommends the use of a lifting crane when handling the pump.
3.2 Installation
Step 1
Always read the technical data thoroughly.
Always use of a lifting crane when handling the pump.
(See chapter 6 Technical data).
Always have the pump electrically connected by authorized
personnel.
(see the motor instruction).
CAUTION
Alfa Laval cannot be held responsible for incorrect
installation.
Step 2
Ensure that there is sufficient clearance around the pump (min.
0.5 m)(1.64 ft).
NOTE!
US pumps have no shroud
TD 241-005/1
Step 3
Check that the flow direction is correct. Outlet Correct!
Inlet
TD 241-006
Step 4
1. Ensure that the pipelines are routed correctly.
2. Ensure that the connections are tight.
Remember
Seal rings!
TD 241-007
Few bends
Correct!
Step 5
Avoid stressing the pump.
Pay special attention to:
-Vibrations
- Thermal expansion of the tubes
- Excessive welding
-Overloading TD 241-008/1
Avoid
bending
pipelines
8

3 Installation
Study the instructions carefully and pay special attention to the warnings!
SolidC is with impeller screw as standard.
Check the direction of rotation of the impeller before operation.
- See the indication label on the pump.
3.3 Pre-use check
Step 1
Never start in the wrong direction of rotation with liquid in the
pump.
1. Start and stop the motor momentarily
2. Ensure that the direction of rotation of the motor fan is
clockwise as viewed from the rear end of the motor.
See indication label!
Correct
TD 241-013/1
Rear view of motor
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 agreement with local regulations
• Scrapping
- At end of use, the equipment shall be recycled according to relevant, local regulations. Beside 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 the local Alfa Laval sales company.
9

4Operation
Study the instructions carefully and pay special attention to the warnings!
Thepumpisfittedwithawarninglabel indicating correct throttling.
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.
Burning danger!
TD 241-014
Step 3
Never run the pump with both the suction side and the pressure
side blocked.
Explosion danger!
TD 241-015
Step 4
CAUTION
The shaft seal must not run dry.
CAUTION
Never throttle the inlet side.
See the warning label!
Do
not Correct!
run
dry!
TD 241-075 Wrong
Step 5
Flushed shaft seal:
1. Connect the inlet of the flushing liquid correctly.
2. Regulate the water supply correctly.
Free Correct!
outlet
R1/8”
(BSP)
=100°C
Inlet
=1bar(water)
TD 241-021 Tmax
Pmax
10

4Operation
Study the instructions carefully and pay special attention to the warnings!
The pump is fitted with a warning label indicating correct throttling.
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.
Throttling!
11

4Operation
Pay attention to possible faults.
Study the instructions carefully.
4.2 Fault finding
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 (See 4.1 Operation/Control) Replace:
All wearing parts (See 5.1 General
maintenance)
- 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 seals Incorrect rubber grade Change rubber grade
12

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 sterilizing.
Burning danger!
TD 241-014/1
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
Sterilization 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 rules/directives.
Always rinse!
Water Cleaning agent
13

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.
5.1 General maintenance
Step 1
Always read the technical data thoroughly.
(See chapter 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.
Burning danger!
TD 241-014/1
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.
CAUTION
Pay special attention to the warnings!
TD 241-018/1
Atmospherie pressure
required!
Step 4
Recommended spare parts:
Service kits (see chapter 7 Parts list and Service Kits).
Order Service Kits from Service kits list (see chapter 7 Parts list
and Service Kits).
Ordering spare parts
Contact the Sales Department.
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.
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
planning of inspections
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
Silicone grease or silicone oil
The bearings are permantly
lubricated
Pre-use check
CAUTION!
Fit the electrical connections correctly if they have been removed from the motor during service. (See pre-use check).
Pay special attention to warnings!
1. Start and stop the motor momentarily
2. Ensure that the pump operates smoothly.
15

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
* : Relates to the shaft seal.
5.2 Dismantling of pump/shaft seals
Step 1
Removescrews,springwashers,clamps(55)andpumpcasing
(29).
TD 241-012
Step 2
Flushed shaft seal:
Unscrew tubes (42) using a spanner.
TD 241-020/1
*
Step 3
Remove safety guards (22). This is easily done by Lifting out the
safety guards, for exampel with a screwdriver.
TD 241-019/1
Step 4
1. Remove impeller screw (36).
2. Remove impeller (37). If necessary, loosen the impeller by
tapping gently on the impeller vanes. The shaft can be fixed
with a screwdriver in the compression ring.
3. Remove the O-ring (38) from the impeller.
TD 241-022/1
Step 5
1. Pull off the O-ring (26) from back plate (25).
2. Unscrew nuts (20) and remove washers (21) and the back plate.
TD 241-023/1
16

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
* : Relates to the shaft seal.
Step 6
1. Remove the stationary seal ring (11).
2. Remove the O-ring (12) from stationary seal ring (11). *
Use the tool
supplied Left
hand thread
Step 7
Flushed shaft seal:
1. Remove screws (41) and seal housing (40).
2. Pull out lip seal (43) from the seal housing.
*
Step 8
1. Remove the complete shaft seal from stub shaft (7).
2. Remove spring (13) and rotating seal ring (14) from the drive
ring (10).
TD 241-026/1
*
Use the tool supplied. Left hand thread * Alternative dismantling of single shaft seal - Front loading
1. Complete steps 1 through 4.
2. Remove stationary seal ring.
3. Remove o-ring (12) from stationary seal ring (11).
4. Remove complete shaft seal from stub shaft.
5. Remove spring (13) and rotating seal ring (14) from the drive ring
(10).
TD 241-076/1
17

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
* : Relates to the shaft seal.
5.3 Assembly of pump/single shaft seal
Step 1
1. Remove spring (13).
2. Lubricate O-ring (15)andfititinrotatingsealring(14).
NOTE!
Make sure that O-ring (15) has max. clearance from the sealing
surface.
TD 241-030/1
*
Step 2
1. Refit spring (13) on rotating seal ring (14).
2. Fit the spring and the rotating seal ring on drive ring (10).
CAUTION
Ensure that the driver on the drive ring enters the notch in the
rotating seal ring.
TD 241-031/1
*
Step 3
Fit the complete shaft seal on stub shaft (7).
NOTE!
Make sure that connex pin on the stub shaft enters the notch in
drive ring (10). TD 241-032/1
*
Step 4
1. Fit O-ring (12) on stationary seal ring (11) and lubricate.
2. Screw the stationary seal ring into back plate (25).
CAUTION
Only tighten by hand to avoid deforming the stationary seal ring.
(Max 7Nm)
Use the tool supplied
Left hand thread *
Step 5
1. Clean the sealing surfaces with contact cleaner before fitting
back plate (25).
2. Carefully guide the back plate onto adaptor (16).
3. Fit washers (21) and nuts (22).
TD 241-027/1
*
Step 6
Lubricate O-ring (26) and slide it onto back plate (25).
TD 241-028/1
18

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
* : Relates to the shaft seal.
Step 7
1. Lubricate O-ring (38) and fit it in impeller (37).
2. Lubricate impeller hub with silicone grease or oil.
3. Screw the impeller onto stub shaft (7).
4. Fit impeller screw (39) and tighten 20 Nm (7.4 lbf-ft).
TD 241-022/2
Step 8
Fit safety guards (22).
TD 241-019/2
Step 9
Fit pump casing (29), clamps, spring washer and tighten screws
(55).
TD 241-012/2
Use the tool supplied
Left hand thread *
Alternative assembly of single shaft - front loading
1. Fit rotating seal ring (14) and spring (13) on drive ring
(10).
2. Fit complete shaft seal on stub shaft.
3. Fit O-ring (12) onto stationary seal ring (11).
4. Fit stationary seal ring.
5. Complete steps 4 through 1.
CAUTION
Ensure that the driver on the drive ring enters the notch
in the rotating seal ring. TD 241-076/2
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.
* : Relates to the shaft seal.
5.4 Assembly of pump/flushed shaft seal
Step 1
1. Fit O-ring (12) on stationary seal ring (11) and lubricate.
2. Screw the stationary seal ring into back plate (25).
CAUTION
Only tighten by hand to avoid deforming the stationary seal ring.
(Max 7Nm)
Use the tool supplied
Left hand thread *
Step 2
Flushed shaft seal:
1. Fit lip seal (43) in seal housing (40).
2. Lubricate O-ring (44) and slide onto the seal housing (40).
3. Fit the seal housing on back plate (25) and tighten screws (41).
*
TD 241-033/1
Step 3
1. Remove spring (13).
2. Lubricate O-ring(15)andfititinrotatingsealring(14).
NOTE!
Make sure that O-ring (15) has max. clearance from the sealing
surface.
TD 241-030/1
*
Step 4
1. Lubricate O-ring (45) and fit it in drive ring (10).
2. Fit spring (13) and rotating seal ring (14) on the drive ring.
CAUTION
Ensure that the driver on the drive ring enters the notch in the
rotating seal ring.
TD 241-031/1
*
Step 5
Fit complete shaft seal on stub shaft (7) so that connex pin on the
stub shaft enters the notch in drive ring (10).
TD 241-032/1
*
Step 6
1. Carefully guide back plate (25) onto adaptor (16).
2. Fit washers (21) and tighten nuts (20).
Note:
Make sure that holes in the seal housing are in a vertical position
TD 241-027/1
20

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Lubricate the rubber seals before fitting them.
* : Relates to the shaft seal.
Step 7
Lubricate O-ring (26) and slide it onto back plate (25).
TD 241-028/1
Step 8
1. Lubricate O-ring (38) and fit it in impeller (37).
2. Lubricate the impeller hub with silicone grease or oil.
3. Screw impeller (37) onto stub shaft (7).
4. Fit impeller screw (39) and tighten 20 Nm (7.4 lbf-ft).
TD 241-022/2
Step 9
1. Screw tubes (42) into seal housing (40).
2. Tightenwithaspanner.
TD 241-020/2
*
Step 10
Fit safety guards.
TD 241-019/2
Step 11
Fit pump casing (29), clamps, spring washers and tighten screws
(55).
TD 241-012/2
21