Borger Classic FL Series User manual

Börger Rotary Lobe Pump
Classic
Operating Manual
FL Series
www.boerger.de www.boerger.com

Europe Germany
- Head Office -
Börger GmbH
Benningsweg 24
46325 Borken-Weseke, Germany
Germany
Phone
Fax
E-mail
Internet
+49 (0) 2862 / 91030
+49 (0) 2862 / 910346
[e-mail]
www.boerger.de
France Börger France S.A.R.L.
9 rue des Prés
67670 Wittersheim
France
Phone
Fax
E-mail
Internet
+33 (0) 3 / 88515468
+33 (0) 3 / 88515413
[e-mail]
www.borger.fr
Great Britain/
Ireland
Börger UK Ltd.
East Wing - Old School
Watling St. Gailey
Staffordshire
ST19 5PR, United Kingdom
Phone
Fax
E-mail
Internet
+44 (0) 1902 / 798977
+44 (0) 1902 / 798979
[e-mail]
www.boerger.com
Netherlands
Belgium
Luxembourg
Börger Benelux
Postbus 78
7630 AB Ootmarsum
Netherlands
Phone
Fax
E-mail
Internet
+31 (0) 541 / 293687
+31 (0) 541 / 293578
[email protected]
www.boerger-pumps.nl
Poland Boerger Polska Sp.z o.o.
ul. Toszecka 101
44-100 Gliwice
Poland
Phone
Fax
E-mail
Internet
+48 32 / 3356094
+48 32 / 3356095
[e-mail]
www.boerger.pl
America USA Boerger, LLC
2860 Water Tower Place
Chanhassen, MN 55317
USA
Phone
Fax
E-mail
Internet
+1 877 / 7263743
+1 612 / 4357300
+1 612 / 4357301
[e-mail]
www.boerger.com
Asia
Australia /
Oceania
Singapore Boerger Pumps Asia Pte. Ltd.
16 Boon Lay Way
#01-48 TradeHub21
Singapore 609965
Phone
Fax
E-mail
Internet
+65 / 65629540
+65 / 65629542
[e-mail]
www.boerger.com
China Boerger Pumps (Shanghai) Co., Ltd.
Room 1009, No. 939 JinQiao Road
Pudong, Shanghai 200136
Phone
Fax
E-mail
Internet
+86 (0) 21 / 61604075
+86 (0) 21 / 61604076
[e-mail]
www.boerger.com.cn
India Boerger Pumps Asia Pte. Ltd.,
India Representation Office
German Centre, Office #21
14th floor, Building no. 9, Tower B
DLF Cyber City Phase III
Gurgaon 122002 Haryana, India
Phone
Fax
E-mail
Internet
+91 (0) 124 / 4636060
+91 (0) 124 / 4636063
[e-mail]
www.boerger.com
Africa* Head Office Börger GmbH
Benningsweg 24
46325 Borken-Weseke, Germany
Germany
Phone
Fax
E-mail
Internet
+49 (0) 2862 / 91030
+49 (0) 2862 / 910346
[e-mail]
www.boerger.com
Your sales partner:
(Stamp)
* Algeria, Morocco: See France, Börger France S.A.R.L.
Börger Worldwide
BA-Classic FL_en-US, 03.05.2018www.boerger.de / www.boerger.com2

Unit:
Product group:
Type:
Rotary lobe pump
FL 518, FL 776, FL 1036
Precise product specifications for your unit, with the
exception of control units, can be found in the data sheet
enclosed with this operating manual.
Manufacturer’s address:
Company:
Address:
Town / city:
Phone:
Fax:
E-mail:
Internet:
Börger GmbH
Benningsweg 24
46325 Borken-Weseke, Germany
+49 (0) 2862 / 9103 – 0
+49 (0) 2862 / 9103 – 46
[e-mail]
www.boerger.de
Spare parts orders and customer service in Germany:
Phone:
Fax:
E-mail:
+49 (0) 2862 / 9103 – 31
+49 (0) 2862 / 9103 – 49
[e-mail]
Spare parts orders and customer service in other
countries:
See separate contact data for your regional sales partner
Document data:
Document:
Issue date:
Language:
BA-Classic FL_en-US
03.05.2018
English translation of the German original, available at
[e-mail]
Product Specifications
BA-Classic FL_en-US, 03.05.2018 www.boerger.de / www.boerger.com 3

Table of Contents
1General information...................................................................................................... 8
1.1 Introduction...................................................................................................................... 8
1.2 Notes on copyrights and property rights.......................................................................... 8
1.3 Information for the operator............................................................................................. 9
1.4 Training and instruction................................................................................................. 10
1.5 Sample training topics................................................................................................... 11
2 Safety............................................................................................................................ 13
2.1 General Information....................................................................................................... 13
2.2 Notes on signs and symbols.......................................................................................... 13
2.3 Proper use..................................................................................................................... 16
2.4 Residual risk.................................................................................................................. 17
2.5 Qualifications for operating personnel........................................................................... 20
2.6 Personal protective equipment...................................................................................... 23
2.7 Securing the machine against restart............................................................................ 24
2.8 Description of the safety equipment.............................................................................. 25
2.8.1 EMERGENCY STOP..................................................................................................... 25
2.8.2 Coupling guard.............................................................................................................. 26
2.8.3 Intermediate chamber.................................................................................................... 26
2.8.4 Optional monitoring devices.......................................................................................... 26
2.9 Markings and signs........................................................................................................ 27
2.10 Markings and signs to be attached by the operator....................................................... 29
2.11 Safety instructions for operating personnel................................................................... 29
2.12 Safety instructions for maintenance and rectifying malfunctions................................... 30
2.13 Information on special dangers..................................................................................... 36
2.13.1 Oil, grease and other chemical substances................................................................... 36
2.13.2 Noise............................................................................................................................. 36
3 Product Description.................................................................................................... 37
3.1 Construction of the Börger machine.............................................................................. 37
3.1.1 Quick-release cover....................................................................................................... 38
3.1.2 Casing........................................................................................................................... 38
3.1.3 Rotors............................................................................................................................ 39
3.1.4 Timing gear.................................................................................................................... 40
3.1.5 Shaft seal....................................................................................................................... 40
3.1.6 Intermediate chamber (quench).................................................................................... 41
3.1.7 Designs, mounting positions.......................................................................................... 42
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3.1.8 Pipe connections on inlet and outlet.............................................................................. 44
3.1.9 Units / drive options....................................................................................................... 46
3.1.10 Options and accessories............................................................................................... 47
3.2 Operating principle........................................................................................................ 48
3.3 Technical data................................................................................................................ 49
3.3.1 Dimensions.................................................................................................................... 49
3.3.2 Performance data and maximum loads......................................................................... 52
4 Transportation, Storage and Installation................................................................... 55
4.1 Transportation................................................................................................................ 55
4.2 As-delivered condition................................................................................................... 57
4.3 Storage and interim storage.......................................................................................... 58
4.3.1 Storage.......................................................................................................................... 58
4.3.2 Interim storage............................................................................................................... 61
4.4 Installation..................................................................................................................... 62
4.4.1 Preparation for installation............................................................................................. 62
4.4.2 Positioning..................................................................................................................... 66
4.4.3 Installing the inlet and outlet.......................................................................................... 68
4.4.4 Aligning the unit............................................................................................................. 71
4.4.5 Electrical, hydraulic and PTO shaft connection............................................................. 73
4.5 Checks before commissioning....................................................................................... 79
4.5.1 Checking smooth running following storage and long downtimes................................. 80
4.5.2 Checking readiness for operation.................................................................................. 81
4.5.3 Checking the flow direction............................................................................................ 83
5 Operation...................................................................................................................... 86
5.1 Commissioning.............................................................................................................. 89
5.1.1 Test run with medium..................................................................................................... 90
5.1.2 Complete commissioning.............................................................................................. 91
5.2 Continuous operation.................................................................................................... 92
5.3 Downtimes..................................................................................................................... 93
5.4 Emergency shut-down................................................................................................... 94
5.5 Malfunctions.................................................................................................................. 95
5.6 Measures following on demand work!......................................................................... 104
6 Maintenance and Repairs......................................................................................... 105
6.1 Machine care............................................................................................................... 106
6.1.1 Cleaning the outside.................................................................................................... 108
6.1.2 Pressure relief............................................................................................................. 109
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6.1.3 Cleaning the inside....................................................................................................... 111
6.2 Maintenance and inspection........................................................................................ 114
6.2.1 Maintenance and inspection plan................................................................................ 114
6.2.2 Lubricant fill level and changing the lubricants............................................................ 116
6.3 Repairs........................................................................................................................ 123
6.3.1 Notes on repair work................................................................................................... 123
6.3.2 Opening and closing the quick-release cover.............................................................. 125
6.3.3 Rotors, removal and replacement............................................................................... 128
6.3.4 Replacing the mechanical seal.................................................................................... 149
6.3.5 Replacing the casing liners.......................................................................................... 159
6.3.6 Replacing the gear-side casing protection plate.......................................................... 163
6.3.7 Other repairs................................................................................................................ 165
6.3.8 Measures following repair and maintenance work!..................................................... 165
6.3.9 Queries........................................................................................................................ 166
7 Disposal...................................................................................................................... 167
7.1 Environmental protection............................................................................................. 167
7.2 Oil, oily waste and grease........................................................................................... 167
7.3 Plastics........................................................................................................................ 167
7.4 Metals.......................................................................................................................... 168
7.5 Electrical and electronic waste.................................................................................... 168
7.6 Final decommissioning................................................................................................ 168
8 Accessories............................................................................................................... 169
8.1 Frequency converter.................................................................................................... 169
8.2 Monitoring equipment.................................................................................................. 169
8.2.1 Dry run protection........................................................................................................ 169
8.2.2 Pressure monitoring devices as overpressure protection............................................ 170
8.2.3 Pressure relief valve with bypass................................................................................ 170
8.2.4 Level monitor with float switch..................................................................................... 171
8.3 Auger feed................................................................................................................... 171
9 Appendix.................................................................................................................... 172
9.1 Data sheet................................................................................................................... 172
9.2 Wear parts................................................................................................................... 172
9.3 Assembly drawing....................................................................................................... 175
9.3.1 Rotary lobe pump........................................................................................................ 176
9.4 Spare parts list............................................................................................................. 177
9.4.1 Tools / installation aid.................................................................................................. 180
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9.5 Parallel keys................................................................................................................ 183
9.6 Checklist for commissioning........................................................................................ 183
9.7 EU Declaration of Conformity / EU Declaration of Incorporation................................. 185
9.7.1 EU Declaration of Conformity...................................................................................... 185
9.7.2 EU Declaration of Incorporation.................................................................................. 186
9.8 Lubricant list................................................................................................................ 187
9.8.1 Börger gear units......................................................................................................... 188
9.8.2 Buffer fluid................................................................................................................... 189
9.8.3 Oil properties............................................................................................................... 190
9.8.4 Oil types....................................................................................................................... 192
9.8.5 Oil filling quantity of the Börger units........................................................................... 195
9.8.6 Lubricant orders........................................................................................................... 197
9.8.7 Customer approval for special lubricants (example)................................................... 198
9.9 Additional documentation............................................................................................ 199
9.10 Supplier documentation............................................................................................... 199
10 Index........................................................................................................................... 200
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1 General information
1.1 Introduction
This operating manual is an important aid for the correct and safe
operation of the Börger machine.
It contains important information for operating the Börger machine
in a safe, proper and economical manner.
Adhering to these instructions will help avoid associated dangers,
reduce repair costs and downtimes and increase the reliability and
service life of the Börger machine.
The operating manual must be made available at all times. All per-
sonnel who work on or with the Börger machine must read and
adhere to the manual. This work includes:
— Operation and troubleshooting
—Maintenance (machine care, maintenance and repairs)
— Transportation.
1.2 Notes on copyrights and property rights
This operating manual must be treated as confidential. It may only
be made accessible to authorized persons. The manual may only
be passed on to third parties following written approval from
Börger GmbH.
All documents are protected according to the copyright laws. The
distribution and reproduction of documents, in whole or in part,
plus the exploitation and distribution of all associated content is
forbidden unless expressly authorized in writing.
Violations will be prosecuted and may lead to claims for compen-
sation. All rights for exercising industrial property rights are
reserved by Börger GmbH.
General information
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1.3 Information for the operator
The operating manual is an integral part of the Börger machine.
The operator is responsible for making the operating personnel
aware of this manual.
Additionally, the operator is obligated to ensure the notice and
observance of national regulations for accident prevention and
environmental protection, plus the notice and observance of super-
vision and reporting duties taking special operational aspects into
account, e.g. regarding work organization, work processes and
personnel.
Aside from the operating manual and the currently valid accident
prevention regulations in the country of operation and at the instal-
lation site, all recognized special regulations for safe and proper
operation must be observed.
The operator is not permitted to make or arrange for any changes,
modifications or alterations to the Börger machine without approval
from Börger GmbH.
Any spare parts used must comply with the technical requirements
specified by Börger GmbH. This is always guaranteed when orig-
inal spare parts are used. Only original spare parts may be used
during the warranty period, failing which the warranty is void.
Only trained or instructed personnel may be assigned to operate,
maintain, repair or transport the Börger machine. Clearly define the
personnel responsible for operation, maintenance, repair and
transportation.
General information
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1.4 Training and instruction
As the operator, you are obligated to inform and, if necessary,
instruct your operating personnel in regard to the applicable legal
and accident prevention regulations, as well as the available safety
equipment on the Börger machine.
This obligation also applies to all other safety equipment on and
around the Börger machine. The different technical qualifications
of the operating personnel must be taken into account. The oper-
ating personnel must have fully understood the instructions, and
adherence to the instructions must be guaranteed. Only then can
your personnel work safely and be fully aware of associated risks.
Adherence to instructions must be checked on a regular basis. As
the operator, you should therefore have each instructed staff
member confirm their training participation in writing.
Sample training topics and a sample form for confirming participa-
tion in the training/instruction can be found on the following pages.
Börger GmbH, their regional subsidiaries or your local sales
partner will be happy to help you regarding staff instruction. They
can also carry out training on the functionality, commissioning,
maintenance and repair of the Börger machine, on request.
Contact us for a detailed quotation.
General information
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1.5 Sample training topics
1. Operational safety
— Accident prevention regulations
—General legal regulations
— General safety instructions
— Measures in the event of emergencies
— Safety instructions for operating the Börger machine
— Using the safety equipment on the Börger machine
— Safety equipment on and around the Börger machine
— Explanation of symbols and signs
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
2. Operating the Börger machine
— Using the operating elements on the Börger machine
— Explanation of the operating manual for operating personnel
— Specific experiences in using the Börger machine
— Troubleshooting / dealing with malfunctions
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
3. Repair and maintenance regulations
— Correct handling of cleaning agents and lubricants
—Specific experiences regarding repair, maintenance, cleaning and care of the Börger machine
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
General information
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Confirmation of Training
Training topic
Date: Trainer: Trainer signature:
No. Surname, first name Signature
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
General information
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2 Safety
2.1 General Information
The Börger machine has been developed and constructed
according to current state-of-the-art technology and recognized
safety guidelines in observance of the valid safety regulations in
the country of manufacture.
However, operation of the Börger machine may endanger the
operating person and cause damage to the Börger machine or
other material assets in the following circumstances:
— When operated by untrained or uninstructed personnel
— When not used properly
— When not maintained or repaired properly
2.2 Notes on signs and symbols
The following terms, signs and symbols are used in this operating
manual, and indicate particularly important information.
DANGER!
Warns of an immediate hazardous situation with unavoidable
serious injuries or death as a result if the instructions shown are
not strictly adhered to.
WARNING!
Warns of a hazardous situation with the possible risk of subse-
quent serious injuries or death if the instructions shown are not
strictly adhered to.
CAUTION!
Warns of a possible hazardous situation with the risk of subse-
quent moderate or light injuries and material damage if the
instructions shown are not strictly adhered to.
Safety
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NOTICE!
Indicates a possible hazardous situation or unsafe, dangerous
work processes that may lead to damage to the machine or sur-
rounding area.
NOTE!
Offers useful information on safe and proper operation.
Arrow symbols describe work and/or operational steps. These
steps must be carried out in the sequence of the numbering.
— Indents indicate lists.
Ä Arrow symbols indicate references to further chapters.
WARNING!
Danger due to illegible signage!
Over time, stickers and signs can get soiled or become illegible
due to other reasons, so that dangers are not recognized and
necessary operating instructions cannot be observed. This poses
a risk of injury.
— Do not remove any safety notes, warnings and operating
instructions.
— Keep them completely legible.
— Replace damaged signs or stickers immediately.
Safety
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NOTE!
Illustration of work steps:
Some of the diagrams and photographic images used in this
operating manual, which are only used to illustrate a function or a
particular work step, show a different type of device, however the
functional principle or work step is the same.
Safety
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2.3 Proper use
The rotary lobe pump is a self-priming, valveless positive displace-
ment pump.
The rotary lobe pump delivers the pumped medium specified in the
data sheet continuously, at speed-proportional flow rates, in a
gentle, low-pulsation procedure.
NOTE!
Proper use
The rotary lobe pump or entire unit is configured exclusively
for the operating conditions entered in your request/order
and specified in the order confirmation and enclosed data
sheet.
— Observe the technical specifications in the data sheet.
—Therefore, proper use is restricted to the specified flow
medium, temperatures, speeds and output only.
Proper use includes compliance with the instructions on
— safety,
—operation and control,
— repairs and maintenance,
specified in this operating manual.
Any other use or use over and above these specifications is
deemed as improper use. The operator of the Börger machine is
solely liable for any resulting damage.
Safety
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2.4 Residual risk
Even when all safety instructions are adhered to, there are residual
risks involved in operating the Börger machine as detailed below.
All persons that work on and with the Börger machine must be
aware of these residual risks and observe the associated instruc-
tions to avoid accidents or damage caused by these residual risks.
It may be necessary to remove on-site safety equipment during
installation and when making modifications. This causes a residual
risk and potential danger that each operating person must be
aware of:
DANGER!
Risk of fatal injury due to electric power!
There is an immediate risk of fatal electric shock if live compo-
nents are touched. Damage to the insulation of the individual
components can be fatal.
— Have all work on the electrical equipment performed by skilled
electricians.
—In the event of damage to the insulation, cut off the power
supply immediately and initiate repairs.
— Before working on live components of electrical systems and
equipment, de-energize these components and secure them
in this state for the duration of the work. Adhere to the fol-
lowing safety rules in this regard:
— Disconnect.
— Secure against restart.
— Verify that components have been de-energized.
— Ground and short-circuit.
— Cover or shield any adjacent live components.
— Never bypass or disable any fuses. Comply with the correct
amperage specification when replacing fuses.
— Keep moisture away from all live components. This may lead
to short circuits.
Electric current
Safety
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DANGER!
Risk of injury due to rotating parts!
Moving parts can cause severe injury.
— Do not reach into rotating parts or handle rotating parts when
the machine is in operation.
—Never open protective covers when in operation.
—Perform work on the Börger machine only when stationary.
— Observe the delay time: Prior to opening protective covers,
make sure that all components have stopped moving.
— Shut down the Börger machine and upstream and down-
stream system components as described in
Ä Chapter 5.3
“Downtimes” on page 93 before carrying out any work on the
Börger machine or accessories.
— The operating person is obligated to check that all safety
equipment is installed as described in
Ä Chapter 2.8
“Description of the safety equipment” on page 25 and fully
functional before putting the machine into operation.
— The Börger machine must only be switched on when the
inlet and outlet connections have been established and the
maintenance openings have been securely installed.
CAUTION!
Risk of burns!
Particularly when used outside at correspondingly high ambient
temperatures and high medium temperatures, individual parts of
the Börger machine can become hot and should not be touched
during operation.
Stop the feed and shut down the Börger machine prior to any
troubleshooting, maintenance and repair work on the Börger
machine and the accessories.
Allow the system to cool down completely, if necessary, before
carrying out troubleshooting, maintenance and repair work.
Avoid dust formation as this contributes to heat build-up.
Moving parts
Hot surfaces
Safety
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WARNING!
Risk of serious injuries caused by liquid spouting out or
escaping gases!
Gases or liquids may escape uncontrollably from seals and screw
connections. Especially when flange connections are released
and maintenance openings are opened, pressurized liquid can
spout out at the cover.
Never loosen connections when the unit is pressurized.
— Ensure that all valves and shut-off devices on the inlet and
outlet are closed.
— Depressurize and empty the Börger machine through a
drainage device, if available.
— Immediately absorb escaping media using suitable agents
and dispose of it in accordance with the applicable local regu-
lations.
— Therefore, wear your personal protective equipment (PPE) as
described in
Ä Chapter 2.6 “Personal protective equipment”
on page 23 when opening the cover and take all necessary
precautions.
CAUTION!
Health hazard due to residues of dangerous medium inside
and on the Börger machine!
There is an increased health hazard from contact with the
medium and contaminated components.
Generally, the following applies:
—When using dangerous or health-endangering media, take all
necessary safety measures when performing work on the
Börger machine.
— Avoid direct contact with the medium (skin/eye contact, swal-
lowing, inhaling).
— Remove spillage from your skin without delay.
— Do not store or consume beverages, food or tobacco in the
working area.
Spouting liquids
Health protection
Safety
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2.5 Qualifications for operating personnel
WARNING!
Personnel with insufficient qualifications represent a hazard!
Insufficiently qualified personnel are not able to assess the risks
when using the machine and expose themselves and others to
the risk of serious or fatal injuries.
— All work must only be performed by personnel with the appro-
priate qualifications.
—Keep insufficiently qualified personnel away from the working
area.
The various tasks described in this manual impose different
requirements on the qualifications of personnel who are entrusted
with these tasks.
Only personnel of whom it can be expected that they perform
these tasks reliably, are approved for all tasks. Persons whose
capability to react is impaired, for instance through drugs, alcohol,
or medication, are not approved.
The operating personnel must have been informed or instructed on
the applicable legal and accident prevention regulations as well as
the safety equipment on and around the Börger machine. The
operating personnel must have fully understood the instructions,
and adherence to the instructions must be guaranteed. Only then
can all personnel work safely and in full awareness of the associ-
ated risks.
— Appoint only trained or instructed personnel.
—Clearly define the personnel responsible for operation, installa-
tion, maintenance and repair.
— In addition, also specify the area of responsibility for the oper-
ating persons and allow them to reject unsafe instructions from
others.
Manufacturer
Certain work may be carried out by manufacturer’s qualified per-
sonnel only. Other personnel is not authorized to carry out this
work. To have this work carried out, please contact our customer
service.
Safety
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