Circor IMO OptiLine ACE3 User manual

OACE3 0601.04 en-GB, ID-No.: 176-622/0
Opti Line
ACE3
Maintenance & Start up Instruction
Screw pump

OACE3 0601.04 en-GB, ID-No.: 176-622/0
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Indentication of safety instructions
Non complience of safety
instructions identied
by the this symbol could affect
safety for persons.
cSafety instructions where
electrical safety is in-
volved are identied in this way.
Safety instructions which
shall be considered for
reasons of safe operation of the
pump or pump unit and/or protec-
tion of the pump or pump unit
itself are marked by this sign.
Contents
Installation 3
Transport and storage.......................................................................................................................................... 3
Lifting of pump ..................................................................................................................................................... 3
Pipe connections ................................................................................................................................................. 4
Suction line ..........................................................................................................................................................4
Discharge line ...................................................................................................................................................... 4
Deaeration ........................................................................................................................................................... 4
Strainer ................................................................................................................................................................ 5
Liquid trap ............................................................................................................................................................ 5
Gauges ................................................................................................................................................................6
Pressure relief valve ............................................................................................................................................ 6
Pressure testing and ushing .............................................................................................................................. 6
Start-up 7
Before starting ..................................................................................................................................................... 7
Direction of rotation.............................................................................................................................................. 7
Starting ................................................................................................................................................................ 7
Setting the pressure relief valve .......................................................................................................................... 7
Trouble shooting 8
Components 10
List of components............................................................................................................................................. 10
Exploded view.................................................................................................................................................... 11
Ordering code .................................................................................................................................................... 11
Sectional view.................................................................................................................................................... 12
Service and maintence 13
Service intervals ................................................................................................................................................ 13
Inspection of rotors ............................................................................................................................................ 13
Useful tools ........................................................................................................................................................ 14
Magnetic coupling.............................................................................................................................................. 14
Dismantling ........................................................................................................................................................ 14
Reassembly ....................................................................................................................................................... 18

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Installation
BEFORE COMMENCING ANY WORK, READ THIS INSTRUCTION CAREFULLY!
Design limitations and technical data for each pump are found in the Product description.
Installation of an IMO AB ACE pump does not require special skills. However, these instructions presume that the work is carried out by
experienced tters.
1 Failure to comply with these instrutions
may cause damage and personal injury!
2 The installation must always be designed
to minimise damage, should an
operational or functional failure occur.
E.g. precautions should be considered to
collect oil spillage due to a broken pipe or
pump housing, to stop pump operation if
overheating should occur or if the oil vol-
ume is below a minimum tank level
Fig 1 Clean and dry environment
Fig 2 Lifting of pump
3 When tting the shaft coupling, do not use a
hammer or similar as this may damage the
ball bearing and shaft seal.
Use some kind of press tool.
4 When handling liquids that may harm skin
use gloves and/or protective clothing.
5 When handling liquids which may involve
re hazards appropriate precautions to
avoid danger are to be taken.
Transport and storage
Always protect the pump against ingress of water
and other impurities. Store the pump in a clean, dry
and warm environment. The pump is delivered with
the internals oiled and with protective covers over the
pipe connections and drain openings. These covers
should remain in place for as long as possible during
the mounting and installation procedure but must be
removed before start up.
6 All work carried out on the pump has to be
performed in such a manner that risks for
personal injury are minimized!
Lifting of pump
7 The pump should be lifted with straps se-
curely attached to the pump or pump unit,
so that the center of gravity is located
between the straps in order to avoid
tipping of the pump.
Lifting of the complete pump unit with the lifting device
attached to the motor, should be avoided as the motor's
lifting provisions may not be able to carry the combined
weight of the pump and motor.
8Lifting a complete pump unit, using
slings or hooks attached to the pump or
connecting frame may be dangerous since
the centre of gravity of the pump unit may
be higher than the points of attachments.

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9 Measures shall be provided to avoid
accidental contact with the outer magnetic
rotor.
Pipe connections
The pipe work shall be installed and supported so that
no pipe stresses are transfered to the pump body.
The pipe work should be tight in order to avoid leakage
and inltration of foreign particles and/or air.
Shut off valves should be installed in both suction and
discharge pipes, so that the pump can be hydraulically
isolated.
Suction line
The suction pipe should be designed so that the total
pressure drop, measured at the pump inlet ange, does
not exceed the suction capability of the pump.
Make a proper calculation of the suction line including
components such as valves, strainer, pipe bends etc.
Generally, the pressure drop in the suction line should
be as low as possible, which is achieved if the suction
pipe is short, straight and has a suitable diameter.
The velocity in the suction line should be kept in the
range 0.5 - 1.2 m/s. For L.O. circulating systems, we
recommend to keep it as low as possible.
These recommendations may imply piping dimesions,
deviations from the actual port sizes, dependent on
pump speed and other duty conditions. To facilitate
priming at start-up, the suction line should have a
minimum internal volume, not bigger than what can be
displaced (oil lled) by the pump within 30 seconds.
The suction line must be equipped with a port that al-
lows lling the pump before start.
Discharge line
The discharge line should be dimensioned to keep the
velocity in the range 1 - 3 m/s.
Deaeration
In installations with negative suction head, where the
pump might be started against a pressurized system, a
deaeration pipe with an orice (2-3 mm recom mended)
has to be installed. The deaeration pipe should be con-
nected to the outlet pipe’s highest point.
This must also be installed when the pump is used as
an stand-by pump.
Fig. 3 Pipe connection
Fig. 4 Suction line
Fig. 5 Dearation

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Strainer
The pump has to be protected from foreign matter, such
as weld slag, pipe scale, etc., that could enter the pump
via the suction line. If the cleanliness of the system
cannot be guaranteed, a strainer must be installed in
the inlet pipe near the pump. For practical reasons a
suction strainer with 0.5 - 0.8 mm mesh openings is
recommended:
The size of the strainer should be selected so that it is
large enough to allow adequate pressure at the pump
inlet. The pressure drop across the strainer should
preferably not exceed 0.1 bar at max. ow rate and nor-
mal operating viscosity. A vacuum gauge between the
strainer and the pump inlet is recommended to indicate
when the strainer needs cleaning.
Liquid trap
In some mounting arrangements the pump may not
retain the liquid at stand still. In such installations the
suction pipe should be arranged so it forms a liquid trap
together with the pump, keeping the pump half lled
with liquid. See g. 7.
Fig. 6 Strainer
Fig. 7 Liquid trap

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Gauges
Gauges for monitoring the pump’s working conditions
are recommended. These gauges should be placed
readable as close to the pump’s in- and outlet anges
as possible. On standard pumps, series ACE there are
gauge connections for both in- and outlet.
Pressure relief valve
All systems with screw pumps must be equipped with a
pressure relief valve installed immediately adjacent to
the pump.
This pressure relief valve is an integral part of the
Opti Line ACE to protect the system against excess
pressure.
When liquid is circulated through the valve it heats up in
proportion to the set pressure level and the percentage
of by-passed liquid. 100% by-pass can only be tolerated
for less than about 3 minutes, 80 % by-pass generally
for unlimited periods of time.
If more than 50% recirculation is anticipated, a value
specic to each application should be determined by
closely monitoring the pump body temperature.
If the pump is operating in line with a separate pressure
control valve (see g. 9), the setting of the relief valve
should be high enough so as not to interfere with the
control valve. Likewise, if two pumps are operating in
parallel, the setting should be such that interference
between the two valves is avoided.
Pressure testing and ushing
The system must be ushed and pressure tested before
connecting the pump. If corrosive liquid, such as water
is used, the system must be thoroughly drained, dried
and protected against corrosion after having been
ushed.
10 Oil leakage may make the oor slippery
and cause personal injury.
EDU
Fig. 9 Pressure relief valve
Fig. 10 External control with pressure relief valve
Fig. 8 Gauges

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Start-up
Before starting
After installation and whenever it can be assumed that
the pump has been emptied, the pump must be thor-
oughly lled with liquid. See g 11.
11 Make sure the prime mover is locked out
and can not be started accidentally.
Rotate the shaft by hand while lling the pump, to
ensure that the rotor bores and magnetic couplings are
lled. This is done by rotating the fan on the electric mo-
tor after removing the fan cover.
12 Do not forget to t the motor fan cover
again before making start of motor
possible.
If the suction pipe cannot be completely lled, it is
important to ensure that the trapped air is evacuated
without any pressure build up. (See g. 5 Deaeration).
13 Starting a dry pump is likely to cause
damage to the pump and it's bearing and
magnetic coupling.
Direction of rotation
When the pump is ready to be started, switch the motor
briey on and off and check that the drive motor rotates
in the correct direction as indicated by the rotation ar-
row.
The arrow is placed on different spots depending on the
pump series.
14 Don't mix up with arrow for inlet and outlet!
Starting
Check that all valves necessary for the operation are
fully opened in both discharge and suction lines.
The rst time, the pump should be started with the ad-
justing spindle of the pressure relief valve tightened to
half of the available turns (the valve setting is increased
when the spindle is turned clockwise).
By monitoring the pressure gauge it can be determined
when the suction line is primed and the pump begins to
work. Should the pump not operate normally soon after
start, stop the pump within half a minute. Start again
after about 3-5 minutes and run for half a minute. This
procedure may need to be repeated a couple of times if
the suction line is long. Should the pump still not work, it
must be assumed there is a problem in the system that
needs to be remedied. Check the suction line calcula-
tion on page 4 and/or see ”Trouble shooting”, page 8.
Setting the pressure relief valve
The setting of the opening pressure is made as follows:
Tighten the valve spindle by rotating clockwise to the
maximum extent. The system pressure is regulated by
throttling to required value.
Fig. 11 Filling the pump
Fig. 13 Direction of rotation
The pressure relief valve is eased until the pressure is
just beginning to decrease by turning the spindle CCW.
The valve is now preset for desired opening pressure.
Open the throttling valve entirely.
15 If operating temperature exceeds 60°C
(149°F), appropriate measures to avoid
skin contact shall be provided.
16 Use hearing protections whenever high
noise can be expected from pump, motor
and/or environment.

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Problem Cause What to do
Wrong direction of
rotation
- Electric cables to motor wrongly con-
nected.
Reverse the terminal connection on electric
motor.
17 Connecting and discon-necting
of electric cables must be
done only by personnel
authorized to do such work.
The pump cannot be
primed
- Wrong direction of rotation. See above.
- Suction line is not open or pressure
drop in the suction line is too high.
Check all components in suction line. The
inlet condition should be checked with a
vacuum gauge at the pump inlet.
Check oil viscosity.
- Major air leakage into the suction line. Check the suction line.
- The pump cannot evacuate the air
through the discharge line due to
excessive counter pressure.
See the chapter on Deaeration (page 4).
No ow - The pump is not primed. See above.
- The pressure relief valve is set be-
low the counter pressure or outlet is
blocked.
Check outlet line. Readjust the pressure
relief valve to a value above counter pres-
sure.
Flow too low - The pressure relief valve is set too low
(Discharge pressure also low).
Readjust the pressure relief valve
- Something is restricting the ow in the
suction line. (This would usually cause
noise).
Check all components in the suction line
(strainers, valves etc.).
- The pumped liquid contains a sig-
nicant amount of compressible gas,
such as free air. (This would usually
cause noise).
See next page, Noise and Vibration
(page 9).
Pressure too low - The pressure relief valve is set too
low.
Readjust the pressure relief valve.
- Counter pressure in the discharge line
is too low due to a major leakage.
Check the components in the discharge
line inclusive the recipients.
- The valve piston is stuck in open posi-
tion.
Check the valve. See Installation & Ser-
vice instruction for respective pump.
- Something is restricting the ow in the
suction line. (This would usually cause
noise).
Check all components in the suction line
(strainers, valves etc.).
- The pumped liquid contains a sig-
nicant amount of compressible gas,
such as free air. (This would usually
cause noise).
See next page, Noise and Vibration
(page 9).
- A too small pump has been chosen. Contact your IMO AB representative.
Trouble shooting

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Pressure too high - The pressure relief valve is set too
high.
Readjust the pressure relief valve.
- The oil is too cold (or has higher vis-
cosity than anticipated).
Reduce the pressure setting until opera-
tional temperature has been reached.
- Counter pressure in the discharge line
is too high.
Check the discharge line.
Drive motor difcult
to start or tends to
stop by tripping the
motor overload relay
- Counter pressure too high. See above: Pressure too high.
- Liquid too cold. Readjust the pressure relief valve to a
lower value. Thus the power consumption
for the pumping is relieved and overloading
due to the high viscosity may be avoided.
When the liquid has reached normal tem-
perature and thus ows easily, the relief
valve is reset to normal pressure.
- Motor is undersized for the prevailing
conditions.
Check the motor.
- Electrical power supply faulty. Check the motor and motor connection.
- Motor overload relay set too low or is
faulty.
Readjust or replace the relay.
- Incorrect setting of Y/D starter. Readjust the setting of the starting se-
quence. The time before the motor over-
load relay is tripped should not exceed
10-15 seconds.
Noise and vibration - The ow to the pump is insufcient. See previous page, Flow too low (page 8).
18 Monitor
the pump
function and
shut down if
any sign of
malfunction
is noticed
- Insufcient support of pipe work. Check for pipe vibrations in the pump
connections. Check that the pipes are suf-
ciently clamped.
- Air leakage into the suction line. Check the suction line for air leakage.
- Free air in the liquid or gas cavitation. Contact your IMO AB representative or
IMO AB service department.
- Faulty electrical supply. Check all three phases of the supply.
Disturbance Cause What to do

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List of components
Valid for all pumps in sizes: ACE 025/032/038 Rotor diameter and Generation: D3/L3/K3/N3
With version codes: { N { K { B { P The version code is composed of the letters in the 4 columns.
{ L Example of pump designations std: ACE 025L3 NKBP
{ M
Components
Pos
Components included in spare parts set
No Denomination Qty G012 G054 G057 G070 G098 Notes Explanations:
002 Motor 1G012: Rotor set
003 Connecting frame 1
004 Angle bracket 1G054: Major kit
005 Magnetic coupling 1 x
005A Retaining ring 1 x x x G057: Joint kit
006A Screw 1
007A Screw 1G070: Complete valve element
007B O-ring 1 x x x
1020 Power rotor 1 x x G098: Compl magnetic coupling
105 Nozzle 1 x x 3
112 Balancing piston 1 x x 3
113 Key 1 x x
122 Ball bearing 1 x x
124 Retaining ring 1 x x
124A Support washer 1 x x
202 Idler rotor 2 x x
351 Balancing bush 1 x x
401 Pump body 1Notes:
418 Gasket 1 x x 1
423 Gasket 1 x x 1 1) Gaskets for counter anges
440 Return valve 1
451 Screw 12) Sizes 025-032 only
453 Screw 1
462 Plug 13) Not sold seperately
462A Sealing washer 1 x x
463 Plug 1
463A Sealing washer 1 x x
5010 Front cover 1
506 Gasket 1 x x
520 Cover 1 2
520A O-ring 1 x x 2
551 Rear cover 1
556 Gasket 1 x x
605 O-ring 1 x x x
608 Valve spindle 1 x 3
608A Tension pin 1 x 3
6120 Set screw 1 x 3
613 Pin 1 x 3
614 Valve piston 1 x 3
615 Valve spring 1 x 3
701 Screw 2
701A Washer 2
702 Screw 4
702A Washer 4
703 Screw 3
703A Washer 3
703B Nut 3
998 Drive hub 1
998A Washer 1
998B Screw 1

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Exploded view
- 005
-
702
702A
002
703
004
703A
703B
5010
701A
701
556
506
(614)
(615)
(613)
(608)
(608A)
551
(6120)
605
(501A)
463A
463
451
006A
998
998A
998B
007B
520
520A
124
124A
122
351
113
1020
202
453
462
462A
Part numbers for pump size
Item Spare Parts sets 025 032 038
G012 Rotor set D-lead - -
" K-lead - - 192246
" L-lead 192242 192244 -
" N-lead 192243 192245 192247
G054 Major kit D-lead - - 193065
" K-lead - - 192252
" L-lead 192248 192250 -
" N-lead 192249 192251 192253
G057 Joint kit 192260 192261 192262
G070 Valve element 189873 189873 189873
G098 Magnetic coupling K 192254 192254 -
" L 192255 192255 192258
" M -192256 192259
122 Ball bearing 173765 173765 173591
Recommendation:
For maintenance the following spare
part sets are recommended:
Set: To be used:
G054 Major kit
For repair after damage or greater
wear.
G057 Joint kit
For dismantling the pump.
Ordering example:
For IMO-pump ACE 032N3 NKBP, se-
rial number 456789:
Ball bearing pos 122 p/n 173765
Valve element pos G070 p/n 189873
Ordering code

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Sectional view

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Service intervals
The intervals for inspection and replacement of wear
parts vary greatly with the properties of the pumped
liquid and can only be determined by experience.
Pumping liquid which contains abrasive materials, or
liquid that is corrosive, will signicantly reduce service
life and call for shorter service intervals.
Wear will normally show as unnormal:
• Vibration
• Noise
• Loss of capacity
• Reduction in ow/pressure
19 If the pumps operating temperature
exceeds 60°C let the pump cool off before
any service, maintenance or dismantling
work is commenced to avoid burn injury.
Inspection of rotors
A quick inspection of the idler rotors can be made sim-
ply by removing the rear cover. Note that the driver must
be deenergized and the pump hydraulically isolated
before the rear cover is removed.
If a more thorough investigation is needed, proceed as
under ”Dismantling/Reassembly”.
Service and maintence

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Dismantling
1. Turn the electricity OFF. Close the valves Remove the pump from the system 2. Remove connections screws 701 and wash- ers 701A
Useful tools
Magnetic coupling
A = Puller
B = Screw spanner 16 mm
C = Plastic mallet
D = Allen keys (3 mm & 5 mm)
E = Mounting sleeve, D=25,5 mm
F = Screw driver
G = Plier
H = Guide pins
I = Oil can
M = Screws (006A)
N = Drive hub (998)
O = Screw (998B)
P = Washer (998A)
Q = Outer magnetic rotor
R = Can screws
S = Sealing can
T = Retaining ring
U = Inner magnetic rotor
V = O-ring (007B)
W = Cover (520)
Y = O-ring (520A)

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%
4. Dismount the pump. Be careful with the mag- netic force the rst 5 cm
6. Remove the Sealing can (S)
3. Mount guide pins (H)
5. Dismount can screws (R) using the Allen key (non-magnetc)
7. Remove the o-ring 007B 8. Remove the retaining ring (T)

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10. Remove cover 520 and o-ring 520A 11. Remove cover screws 451 and dismount front cover 5010 and gasket 506
9. Lift cover 520. (Not valid for size 038) 8. Remove the inner magnetic rotor (U)
12.
Remove power rotor 1020 and idler rotors 202 13. Remove retaining ring 124 and support wash-
er 124A

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16. Remove screws 702 between connection frame 003 and motor 002. Dismount connect-
ing frame together with angle bracket 004 17. Release screws 006A to dismount the outer
magnetic rotor (Q). Do not use spanner inside
magnetic rotor!
15. Release spring tension by turning valve spin- dle 608 CCW as much as possible. Loosen
and remove screws 453. Separate the valve
element from the rear cover 551. If neces-
sary, replace the gasket 556 and the o-ring
60514. Dismount ball bearing 122 and balancing bush 351
18. Remove the outer magnetic rotor (Q) 19. Dismount screw 998B and washer 998A and then remove the drive hub 998

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3. Attach the outer magnetic rotor (Q) using screws 006A and non-magnetic Allen key 4. Fit the connection frame 003 on top and fas- ten the washers 702A and screws 702
2. Place the outer magnetic rotor (Q) on the drive hub (N)1. Attach the drive hub 998 using washer 998A and screw 998B
5. Fit the gasket 556 in place and t the valve elements thin end (608) in place in the rear
cover 551. Place the cover on top of the
pump and tighten the screws 453 6. Place the washer 124A and retaining ring 124 on top of the bearing on power rotor 1020
Reassembly

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9. Place the o-ring 520A, cover 520, inner mag- netic rotor (U) and the retaining ring (T) back
in position 10. Place the o-ring 007B and then the sealing cup (S) and tighten all screws (R)
8. Place gasket 506 and front cover 5010 and tighten screws 4517. Reinsert the idler rotors 202 and the power rotor 1020 into the pump
11. Fasten the guide pins (H) before sliding the pump back onto the connection frame 003.
Do not place any ngers between the pump and the connecting frame during assembly! 12. Fasten the pump using washers 701A and screws 701

OACE3 0601.04 en-GB, ID-No.: 176-622/0
Adress:
IMO AB
PO Box 42090, 126 14 Stockholm
Sweden