Colfax Allweiler AE Series Manual

Progressing cavity pump
Operating and maintenance instructions Series AE.N
with instructions for assembly and
disassembly Construction Type RG
Retain the operating instructions for future use!
This is a translation of the original operating instruction.
Refer to the order-specific section of the documentation for operational data, dimensions and other additional
information.
Order No.: Pump ID No.:
Machine No.: Pump model:
Edition BA-2011.04 ALLWEILER AG – Bottrop plant
Print No. 151 999 P.O. Box 200123 ·46223 Bottrop
VM-No. 760.0003 GB Kirchhellener Ring 77-79 ·46244 Bottrop
Germany
Telephone: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: www.allweiler.com
Subject to technical changes!
Important note:
These operating instructions are supplemented with order-specific information.

These operating and maintenance instructions contain notices from the pump
manufacturer. It may be necessary to amend these instructions with
instructions from the company that operates the pump.
Specific notices about operating and maintaining the overall system in which
the pump is integrated are not provided here. These must be provided by the
persons who are responsible for planning and constructing the system
(system manufacturer).
Specific notices of this type regarding operation and maintenance of the overall system in
which the pump is integrated have precedence over the pump manufacturer’s notices. The
systems manufacturer must comply with operational limits at all times!
Refer to the system manufacturer's operating instructions!

Table of contents
760.0003 GB – 151 999 BA-2011.04
Series AE.N
Construction Type RG
iii
Table of contents
1 About these instructions.........................1
1.1 Who should read these
instructions...................................1
1.2 Related documents......................1
1.3 Warning notices and symbols......1
1.4 Technical terms............................2
1.5 Safety notices...............................2
1.6 Keep information accessible........2
1.7 Inspection.....................................2
1.8 Warranty.......................................2
2 Safety.........................................................3
2.1 Dangers of failure to observe
safety notices...............................3
2.2 Proper use....................................3
2.3 Avoiding common mistakes
(examples) ...................................3
2.4 General safety notices .................3
2.4.1 Product safety..............................3
2.4.2 Operator’s responsibilities............3
2.4.3 Personnel responsibilities ............4
2.5 Safety precautions .......................4
2.5.1 Authorized operating personnel...4
2.5.2 Safety measures during normal
operation......................................4
2.5.3 Safety at the place of installation.4
2.6 Maintenance and repair,
removal of malfunctions...............4
2.7 Unauthorized conversion and
production of spare parts .............5
2.8 Impermissible operating
methods .......................................5
2.9 Protective clothing........................5
2.10 Residual risks...............................5
3 Danger points ...........................................6
3.1 Hazards when working with the
system..........................................6
3.2 Dangers of leaks..........................6
3.3 Dangers of electrical energy........6
3.4 Hazards caused by dust ..............6
3.5 Dangers of moving parts..............6
3.6 Danger of hot or cold parts ..........6
3.7 Operating in potentially
explosive atmospheres ................6
3.8 Danger of pumped liquid..............6
4 Design and function.................................7
4.1 Application and area of usage .....7
4.2 Labeling........................................7
4.2.1 Nameplate....................................7
4.2.2 Pump model label ........................7
4.3 Performance data........................ 7
4.4 Design ......................................... 7
4.4.1 Structural design..........................7
4.4.2 Bearing and lubrication................7
4.4.3 Shaft seal.....................................7
4.4.4 Dimensions/ branch
positions/flanges..........................7
4.4.5 Noise level...................................7
4.4.6 Non-ionizing radiation..................7
4.4.7 Operation.....................................7
4.5 Pump unit design......................... 8
4.5.1 Drive ............................................ 8
4.5.2 Shaft coupling and safety
guarding.......................................8
4.5.3 Base plate....................................8
5 Transport, storage, and disposal........... 9
5.1 Packaging.................................... 9
5.2 Transportation ............................. 9
5.3 Preserving progressing cavity
pumps and placing them into
storage......................................... 9
5.3.1 Preserving ...................................9
5.3.2 Storage........................................9
5.3.3 Removing preservative..............10
5.3.4 Preservatives.............................10
5.3.5 Cleaning agent ..........................11
5.4 Disposal..................................... 11
6 Installation and connection ..................12
6.1 Setting up the pump .................. 12
6.2 Foundation................................. 12
6.2.1 Steel frame configuration ..........12
6.2.2 Characteristics of a concrete
foundation..................................12
6.2.3 Fastening the pump unit to the
concrete foundation...................12
6.2.4 Characteristics of a concrete
foundation for cast base plates .12
6.2.5 Mortaring the base plate............12
6.3 Base plate.................................. 13
6.4 Coupling .................................... 13
6.5 Assembling pump and drive...... 14
6.5.1 Space requirement for
maintenance and repair.............14
6.6 Laying the pipes ........................ 15
6.6.1 Nominal widths..........................15
6.6.2 Supports and flange
connections ...............................15
6.6.3 Cleaning the pipes before
installation..................................15
6.7 Safety and inspection
equipment.................................. 15
6.7.1 Pressure gauges .......................15

Table of contents
iv
Series AE.N
Construction Type RG
BA-2011.04 760.0003 GB - 151 999
6.7.2 Safety device in the pressure
line..............................................15
6.7.3 Electrical connections ................16
7 Operation.................................................17
7.1 Preparing for initial start-up........17
7.1.1 Filling the pump with liquid.........17
7.1.2 Pump rotation difficulties............17
7.1.3 Checking the direction of
rotation.......................................17
7.2 Bringing the pump into
operation....................................17
7.2.1 Starting.......................................17
7.2.2 Drive...........................................17
7.2.3 Checking pump capacity............17
7.2.4 Dry-running protection ...............17
7.3 Taking the pump out of
operation....................................17
7.3.1 Stoppage....................................17
7.3.2 Measures for longer periods of
downtime....................................18
7.4 Special applications of the pump18
8 Maintenance cycles and intervals ........19
9 Preventive Maintenance ........................20
9.1 Preventive Maintenance ............20
9.1.1 General monitoring ....................20
9.1.2 Universal joints...........................20
9.1.3 Drive shaft bearing and bearing
lubrication...................................20
9.1.4 Spur gear ...................................20
9.1.5 Shaft seal...................................21
9.1.5.1 Stuffing box................................21
9.1.5.2 Running gear seal......................22
9.1.6 Drive motors and (variable) gear22
10 Maintenance............................................23
10.1 Disassembly and assembly
instructions.................................23
10.1.1 Disassembling the progressing
cavity pump................................23
10.1.2 Removing the stator...................23
10.1.3 Removing the rotor and rotor-
side joint.....................................23
10.1.4 Removing the universal joint
shaft and the drive-side joint......25
10.1.5 Removing the stub shaft and
worm shaft..................................25
10.1.6 Removing the stub shaft on
pump sizes 100 … 2700............25
10.1.7 Removing the drive shaft and
spur gears on pump sizes 100
… 2700.......................................25
10.1.8 Removing the drive shaft on
pump size 5000..........................25
10.1.9 Removing the hollow shaft and
spur gears from pump size 500026
10.1.10 Removing the running gear seal26
10.2 Assembling the progressing
cavity pump ............................... 26
10.2.1 Installing the drive shaft and
spur gears on pump sizes 100
… 2700......................................26
10.2.2 Installing the hollow shaft and
spur gears on pump size 5000..28
10.2.3 Installing the rotor and rotor-side
joint............................................30
10.2.3.1 Tightening with Band-It clamping
tool and adapter J050................ 31
10.2.3.2 Tightening with clamping tool PoK-
It II.............................................. 32
10.2.4 Installing the universal joint
shaft and the drive-side joint .....32
10.2.5 Installing the stuffing box casing33
10.2.6 Installing stub shaft and worm
shaft on pump sizes 100 …
2700...........................................33
10.2.7 Installing the drive shaft and
worm shaft on pump size 5000 .33
10.2.8 Installing the running gear
cartridge.....................................33
10.2.8.1 General information about running
gear seals.................................. 33
10.2.8.2 Design and functionality of the
running gear seal....................... 34
10.2.8.3 Installing the running gear seal . 34
10.2.9 Installing the shaft seal..............36
10.2.10 Installing the stator ....................36
11 Spare parts .............................................38
11.1 Index of spare parts and
recommended spare/reserve
parts........................................... 39
11.2 Sectional drawing for series
AE.N; RG construction type;
sizes 100 … 2700...................... 43
11.3 Sectional drawing for series
AE.N; RG construction type ...... 44
11.4 Sectional drawing for series
AE.N; RG construction type;
size 5000 ................................... 45
11.5 Sectional drawing for series
AE.N; RG construction type ...... 46
12 Causes and removal of operational
faults .......................................................47
13 Clearance certificate..............................49
14 Declaration according to EC
machinery directive...............................50

Table of Figures
760.0003 GB - 151 999 BA-2011.04
Series AE.N
Construction Type RG
v
Table of Figures
Fig. 1 Nameplate (example)............................7
Fig. 2 Model code............................................7
Fig. 3 Check for twisting................................13
Fig. 4 Check coupling alignment...................13
Fig. 5 Check lateral and height misalignment14
Fig. 6 Check angular misalignment...............14
Fig. 7 Removing the joint clamp....................24
Fig. 8 Removing the joint sleeve ...................24
Fig. 9 Removing the bushes for joint bolt......24
Fig. 10 Installation position of the spur gears27
Fig. 11 Installation position of the spur gears29
Fig. 12 Pressing in the joint bush ..................30
Fig. 13 Securing the joint sleeve 67 .............31
Fig. 14 Apply pressure to the joint clamp strap
on the joint clamp seal. .................31
Fig. 15 Band-It clamping tool and adapter J050
......................................................31
Fig. 16 Tightening the joint clamps................32
Fig. 17 Shearing off the joint clamp...............32
Fig. 18 Canting and shearing off the joint
clamp.............................................32
Fig. 19 Installing running gear seal ...............35
Fig. 20 Position of running gear seal.............35
Fig. 21 Installing running gear seal ...............36
Fig. 22 Sectional drawings of series AE.N; RG
construction type; sizes 100 … 2700
......................................................43
Fig. 23 Sectional drawings of series AE.N; RG
construction type...........................44
Fig. 24 Sectional drawings of series AE.N; RG
construction type; size 5000 .........45
Fig. 25 Sectional drawings of series AE.N; RG
construction type...........................46
Fig. 26 Clearance certificate..........................49
Listing of Tables
Tab. 1 Who should read these instructions ....1
Tab. 2 Other applicable documents................1
Tab. 3 Overview of dangers............................1
Tab. 4 Symbols and their meaning.................1
Tab. 5 Valvoline preservatives......................10
Tab. 6 Cleaning agents.................................11
Tab. 7 Required volumes of joint lubricating oil
......................................................20
Tab. 8 Overview of spur gear unit lubricant
volume..........................................20
Tab. 9 Oil volume for each pump size ..........36
Tab. 10 Single part labeling..........................42
Tab. 11 Overview of potential disturbances..47
Tab. 12 Troubleshooting disturbances .........48

Listing of Tables
vi
Series AE.N
Construction Type RG
BA-2011.04 760.0003 GB - 151 999

About these instructions
Who should read these instructions
760.0003 GB - 151 999 BA-2011.04
Series AE.N
Construction Type RG
1
1 About these instructions
These instructions:
•are part of the pump,
•are valid for the specified series and
construction types,
•describe safe and proper usage in all
phases of operation.
1.1 Who should read these
instructions
Target group Task
Operators
Keep these instructions accessible
for later use at the place where
the system is operated.
Require employees to read and
observe these instructions and
other valid documents, especially
safety and warning notices.
Observe all other stipulations and
regulations related to the system.
Technical
assembly
personnel
Read, observe, and follow these
instructions and related
documents, especially safety and
warning notices.
Tab. 1 Who should read these instructions
1.2 Related documents
Document Purpose
Order data
sheet
Technical specifications, operating
conditions, operating limits
Unit drawing
Setup and connection dimensions,
etc.
Technical
description Technical specifications
Sectional
drawing Sectional drawing, parts numbers, component names
Supplier
documen-
tation
Technical documentation for third-
party parts
List of spare
parts Ordering spare parts
Declaration of
conformity Standards conformity
ATEX
supplemental
instructions
Instructions for operation in
potentially explosive atmospheres.
Tab. 2 Other applicable documents
1.3 Warning notices and symbols
Several names and symbols are used in the
operating instructions to represent hazards
and safety regulations.
Together with written safety notices, the safety
symbols are designed to draw attention to
unavoidable residual hazards during usage of
the machine. These residual hazards are
related to:
•people
•the machine
•other objects
•the environment
Warning notice Level of danger and
consequences for failure to
observe
Danger!
Draws attention to an immediate
danger that could result in death
or serious injury.
Warning!
Draws attention to a potentially
dangerous situation that could
result in death or serious injury.
Caution!
Draws attention to a potentially
dangerous situation that could
result in minor injuries or
property damage.
Caution!
Draws attention to the danger of
electrical shock.
Tab. 3 Overview of dangers
Warning notice Level of danger and
consequences for failure to
observe
Safety symbol
Comply with all measures
identified by the safety symbol in
order to avoid injury or death.
Instructions for action
1. , 2. , … Multi-step instructions for action
Requirement
Cross-reference
Notice!
Draws attention to information
that can contribute to a better
understanding of machine
operations.
Tab. 4 Symbols and their meaning

About these instructions
Technical terms
2
Series AE.N
Construction Type RG
BA-2011.04 760.0003 GB - 151 999
1.4 Technical terms
Pump: "Pump" refers to the pump without
coupling, drive, or any other components.
Pump unit: "Pump unit" refers to the pump with
coupling, drive, and any other components.
1.5 Safety notices
Please carefully read the operating instructions
before beginning work on the system.
Knowledge of basic safety notices and safety
regulations is a fundamental requirement for
safe activities and disturbance-free operation
of this machine.
All persons involved with set-up, start-up,
operation, maintenance, or repair of the
system must be properly qualified or trained
and comply with all aspects of these operating
instructions.
Furthermore, they must comply with accident-
prevention rules and regulations at the place of
usage.
Unauthorized conversions and modifications to
the system are not permitted for safety
reasons.
Notices applied directly to the machine, such
as:
•arrow indicating direction of location,
•safety notices
must be observed at all times and maintained
in a readable condition.
1.6 Keep information accessible
Operating instructions must be retained at the
machine. All persons expected to perform
activities on the machine must have access to
the operating instructions at all times. In
addition to the operating instructions, other
instructions related to the German Work
Protection Law (ArbSchG) and Work
Equipment Ordinance (AMBV) must also be
provided.
All signs containing safety and operating
notices must be kept in readable condition at
all times. Signs that are damaged or become
unreadable must be replaced immediately.
1.7 Inspection
All pumps are subjected to leak and
performance tests before leaving our factory.
Only flawlessly operating pumps that meet our
performance specifications leave the factory.
Therefore, observance of the following
operating instructions will provide the
conditions necessary for disturbance-free
operation.
1.8 Warranty
Our liability for defective products is defined in
our delivery terms. We accept no liability for
damage caused by a failure to observe the
operating instructions and operating
conditions.
If operating conditions change (different liquid,
speed, viscosity, temperature or pressure
conditions) at a later time, we must investigate
and decide on a case-by-case basis whether
the pump is suitable for the new conditions.
Absent special agreements, only we or
authorized and contracted customer service
workshops may during the warranty time
period open or modify the pumps that we
delivered. Only original parts or parts approved
by the manufacturer may be used. Failure to
observe these requirements will remove our
liability for any defects as well as invalidate the
machine’s EC declaration of conformity.

Safety
Dangers of failure to observe safety notices
760.0003 GB - 151 999 BA-2011.04
Series AE.N
Construction Type RG
3
2 Safety
The operating instructions contain important
notices that must be observed during set-up,
operation, and maintenance. For this reason,
the installer and all technical
personnel/operators must read these operating
instructions before installation and operation;
these instructions must remain with the
machine/system at all times. In addition to the
general safety notices listed under this main
section "Safety", all special safety notices
inserted below the other main points, such as
notices applicable to private usage, must also
be observed.
2.1 Dangers of failure to observe
safety notices
Failure to observe the safety notices can result
in dangers for people and the environment as
well damage to the machine. Failure to
observe safety notices will lead to loss of all
damage compensation claims.
In particular, failure to observe safety notices
may result in the following dangers:
•Failure of important functions on the
machine/system.
•Failure of required methods for
maintenance and repair.
•Danger of injury from electrical,
mechanical, and chemical hazards.
•Environmental damages caused by
escape of hazardous materials.
2.2 Proper use
The pump as well as its parts and modules
may be used only for their intended purposes.
Any other or additional usage is improper
usage. ALLWEILER will not be liable for any
resulting damages.
Proper use also refers to observation of all
notices in the operating instructions and
completion of inspection and maintenance
tasks.
Use only original spare parts, wearing parts,
and accessories. These parts are designed
specifically for the system. There is no
assurance that third-party parts are designed
to withstand operating loads and safety
specifications.
We do not approve the use of any parts or
special equipment that we did not deliver.
2.3 Avoiding common mistakes
(examples)
•Always observe the pump’s operational
limits regarding temperature, pressure,
capacity, viscosity, and speed.
(order data sheet)
•If pumping liquids loaded with solids,
comply with limitations on the proportion of
solids and grain size.
(order data sheet, technical description)
2.4 General safety notices
2.4.1 Product safety
The pump was built according to the current
state of technology and recognized safety
regulations. Despite this, dangers to life and
limb of the user or other persons or damage to
the pump or other property remain possible.
•Operate the pump in accordance with
these instructions and in a technically
flawless condition and use it only in the
proper manner with awareness of safety
and dangers.
•Keep these instructions and related
documents in their entirety in readable
condition and keep them available at all
times.
•Prohibit any activity that will endanger your
employees or unrelated third parties.
•In the event of a potentially dangerous
failure of the pump, stop the pump
immediately and have the disturbance
removed by the responsible person.
•In addition to the documentation, comply
with all legal and other safety and
accident-prevention regulations as well as
applicable standards and directives in the
country of operation.
2.4.2 Operator’s responsibilities
Work in a safe manner
►Operate the pump in accordance with
these instructions and in a technically
flawless condition and use it only in the
proper manner with awareness of safety
and dangers.
►Ensure compliance and monitoring of:
-proper use
-legal or other safety and accident-
prevention regulations
-safety stipulations controlling the
handling of hazardous materials

Safety
Safety precautions
4
Series AE.N
Construction Type RG
BA-2011.04 760.0003 GB - 151 999
-applicable standards and
directives of the country where the
pump is operated
►Provide access to personal protective
equipment.
2.4.3 Personnel responsibilities
►Observe notices on the pump and keep
them in readable condition, i.e. arrow
indicating direction of rotation.
►Do not remove safety guarding for hot,
cold, and moving parts during operation.
►Use personal protective equipment
whenever necessary.
►Perform work on the pump only when the
pump is shut down.
►Shut off the motor's power supply and lock
it in the off position before all assembly
and maintenance tasks.
►After completing work on the pump, always
properly reinstall the safety equipment.
►Never step on the pump, coupling guard,
and attached parts or use them as a
climbing aid.
2.5 Safety precautions
2.5.1 Authorized operating
personnel
Only authorized and trained personnel may
work on the progressing cavity pump.
Operators must be at least 18 years of age.
Apprentices may work on the system only
under the supervision of an experienced
person.
The operator is responsible for other people
within his area of activity.
Responsibilities for various activities on the
system must be clearly defined and respected.
Lack of clarity regarding responsibilities
represents a safety risk.
All persons who perform activities on the
machine must read the operating instructions
and confirm with their signature that they have
understood the operating instructions.
2.5.2 Safety measures during
normal operation
The progressing cavity pump may be operated
only when all safety devices are fully
functional.
No safety equipment may be removed or taken
out of operation before or during operation of
the system.
Before switching on the system, ensure that no
one will be endangered by starting of the
system.
The system must be regularly checked for
visible damage and functionality of the safety
equipment.
2.5.3 Safety at the place of
installation
Safe access to the system must be provided at
all times.
Do not block any escape paths!
The operator must provide a nonslip, level floor
and adequate illumination in the workplace.
Keep the area immediately surrounding the
system clean at all times.
Children and the public may not have access
to the system.
Safety devices (emergency stop switch) must
be freely accessible and reachable at all times.
2.6 Maintenance and repair,
removal of malfunctions
The operator must ensure that all
maintenance, inspection, and assembly tasks
are performed by authorized and qualified
personnel who have obtained adequate
information through careful reading of the
operating instructions.
Work on the machine may be performed only
when the machine is shut off. Comply under all
circumstances with the shutdown procedures
(Shutdown page 17) described in the
operating instructions.
Pumps or systems that move hazardous
liquids must be decontaminated.
The points listed under the section "Initial
startup" (page 17) must be observed before
bringing the machine back into operation.
Required adjustment, maintenance, and
inspection tasks must be performed according
to schedule.
Operating personnel must be informed before
starting maintenance and repair tasks.
All upstream and downstream parts of the
system and operating media like compressed
air and hydraulics must be secured against
unintentional restarting.

Safety
Unauthorized conversion and production of spare
parts
760.0003 GB - 151 999 BA-2011.04
Series AE.N
Construction Type RG
5
When performing any maintenance,
inspection, and repair tasks, always shut off
the power to the system and secure the switch
against unintentional restarting.
►If possible, lock the main switch and
remove the key.
►Or attach a sign that warns against
restarting.
Immediately after concluding the work, replace
all safety and protection devices, bring them
back into operation, and test their functionality.
2.7 Unauthorized conversion and
production of spare parts
Changes to or conversion of the machine is
permissible only with the approval of the
manufacturer. Original spare parts and
manufacturer-approved accessories promote
safety. Use of other parts will nullify liability for
any resulting consequences.
2.8 Impermissible operating
methods
Operational safety of the delivered machine is
ensured only through proper use as described
in Section 1 of the operating instructions.
Never exceed the limit values specified in the
data sheet.
2.9 Protective clothing
Protective gloves
Wear protective gloves at all times.
Footwear
Wear sturdy, insulated safety shoes with steel
tips. This will protect your feet from falling
parts.
Safety glasses
Wear safety glasses when working near the
shaft seal area.
Clothing
Wear suitable clothing. Do not wear synthetic
items of clothing. These have a risk of catching
fire.
2.10 Residual risks
Functional inspection and/or adjustment
requires unhindered access to the shaft seal.
Danger!
Danger of being drawn in and
trapped. Perform work on the
pump only when the pump is shut
down.

Danger points
Hazards when working with the system
6
Series AE.N
Construction Type RG
BA-2011.04 760.0003 GB - 151 999
3 Danger points
3.1 Hazards when working with the
system
The progressing cavity pump was built
according to the current state of technology
and recognized safety regulations.
Nevertheless, danger to life and limb of the
user or third parties may arise during use of
the pump or damage may occur to the system
or other property.
Dangerous parts of the system include:
•Moving parts,
•Components of the electrical equipment
(mains connection).
Hazardous materials include:
•Poisonous materials,
•Materials that are hazardous to health,
•Acidic materials,
•Irritants,
•Potentially explosive materials,
•Oxidants; highly, easily, and flammable
materials,
•Carcinogens,
•Teratogenic materials,
•Mutagens,
•Materials that are hazardous to humans in
other ways.
3.2 Dangers of leaks
Leaks (such as at the shaft seal) of hazardous
pumped liquids (explosive, poisonous, hot,
etc.) must be led away in such a way that there
is no danger to people or the environment.
Always obey all legally defined directives.
3.3 Dangers of electrical energy
Electrical hazards are present when working
on the pump, such as:
•through direct contact with live parts or
parts that have become energized due to
faulty conditions,
•through electrostatic energy,
•through high voltage and
•through short circuits and overloads.
Only electrical technicians may perform work
on the electrical power supply.
The machine’s electrical equipment must be
inspected on a regular basis. Loose
connections and charred cables must be
removed immediately.
Proper earthing must be provided whenever
there is the potential for electrostatic charges.
If it is necessary to work on live parts, always
work with a second person who can shut off
the main switch in an emergency.
3.4 Hazards caused by dust
When operating pump units in dust-filled
environments (such as in a mill, during
production of particle board, in a baked goods
factory, etc.) regularly clean the surfaces of the
pumps and motors according to the actual
concentration of dust in order to maintain the
cooling effect and eliminate the possibility of
spontaneous ignition. Refer to explosion
protection directives (BGR 104)
3.5 Dangers of moving parts
The safety guarding for moving parts (such as
the coupling) may not be removed while the
machine is in operation.
3.6 Danger of hot or cold parts
If hot or cold parts represent a hazard, these
parts must be secured against contact at the
site of installation.
3.7 Operating in potentially
explosive atmospheres
If the pump or pump unit is operated in
potentially explosive atmospheres, follow the
ATEX supplemental instructions.
3.8 Danger of pumped liquid
Squirting pumped liquid can cause injury or
poisoning. Use the proper protective clothing
whatever working at the pump.

Design and function
Application and area of usage
760.0003 GB - 151 999 BA-2011.04
Series AE.N
Construction Type RG
7
4 Design and function
4.1 Application and area of usage
Progressing cavity pumps are self-priming,
rotating displacement pumps suitable for
pumping and metering low-viscosity and high-
viscosity liquids, neutral or aggressive liquids,
undiluted or abrasive liquids, liquids containing
gases, liquids prone to foaming, and liquids
with fibrous or solid particles.
4.2 Labeling
4.2.1 Nameplate
Fig. 1 Nameplate (example)
1 Pump number
2 Pump model
3 Direction of rotation or pumping
4 Direction of rotation or pumping
5 CE Mark, Year of Manufacture
4.2.2 Pump model label
The model code for progressing cavity pumps
has several components, as shown in this
example:
Series
AE 1 N 200 – RG
Product
Number of stages
Mechanics
Size
Construction type
Fig. 2 Model code
This model code is engraved on the
nameplate.
4.3 Performance data
Refer to the order data sheet for the exact
performance data applicable to the pump.
4.4 Design
4.4.1 Structural design
Self-priming single-, double-, or quadruple-
stage progressing cavity pump. Pumping
elements are the rotor and stator.
Drive torque is transferred via the drive shaft,
stub shaft, and universal joint shaft to the rotor
and via a gear stage to the worm shaft. The
discharge casing, stator, and stuffing housing
are held together by means of external
housing connection screws (clamp bolts).
4.4.2 Bearing and lubrication
Both sides of the universal joint shaft have
liquid-sealed encapsulated pin joints.
Lubrication is provided by joint oil.
The bearing is provided in the bearing bracket
and in the drive assembly cartridge with
lifetime-lubricated antifriction bearing
.
4.4.3 Shaft seal
Uncooled stuffing boxes on the drive side and
running gear seal on stator side.
4.4.4 Dimensions/
branch positions/flanges
Please refer to the unit drawings for
dimensions of the pump and pump unit, for
branch positions, and flange dimensions.
4.4.5 Noise level
The conditions for measuring noise are as
follows: 1 meter away from the pump.
The pump’s noise level Lp (A) is below
70 dB (A).
4.4.6 Non-ionizing radiation
No non-ionizing radiation, such as from
magnetic fields, is emitted from the
progressing cavity pump.
4.4.7 Operation
Self-priming, rotating displacement pump. The
pumping elements are the rotating rotor, the
fixed stator, and the feed or mixing screws.
The rotor and stator contact each other at two
points of their cross-section. When viewed

Design and function
Pump unit design
8
Series AE.N
Construction Type RG
BA-2011.04 760.0003 GB - 151 999
over the length of the pumping elements, these
two points form an equal number of sealing
lines along the length of the pumping
elements. As the rotor turns, the contents
located in the resulting sealed chambers are
moved axially and continuously from the
suction to the pressure side of the pump.
Despite rotation of the rotor, no turbulence
results.
The consistent chamber volumes eliminate
crushing forces and ensure an extremely
gentle, low-pulse pumping action.
4.5 Pump unit design
4.5.1 Drive
Driven by electric motors with or without
explosion protection, gear motors, or variable
gear motors. Other drive types, such as with a
V-belt, are possible.
4.5.2 Shaft coupling and safety
guarding
Shaft coupling according to DIN 740.
A safety guard according to DIN EN 809 is
attached whenever pump, base plate, and
shaft coupling are delivered together.
Warning!
Danger of being caught, wound,
drawn in and trapped.
In accordance with accident-
prevention regulations, the pump
may be operated only with safety
guarding according to DIN EN 809!
►If safety guarding is not
included, the operator must
install safety guarding.
4.5.3 Base plate
Horizontally-installed pumps are usually
installed with the drive on a shared base plate.
Unless specified otherwise by the operator, the
base plate is made of steel.

Transport, storage, and disposal
Packaging
760.0003 GB - 151 999 BA-2011.04
Series AE.N
Construction Type RG
9
5 Transport, storage, and disposal
5.1 Packaging
Observe the graphical symbols on the
packaging.
The pump’s suction and pressure sides and
auxiliary connections must be closed with
plugs during transport and storage.
►Remove the plugs when installing the
pump unit.
5.2 Transportation
The pump or pump unit must be transported
safely to the place of installation, if necessary
through the use of lifting gear.
Danger!
Be aware of the danger of falling
and loss of stability. Observe the
requirements for lifting in
accordance with VBG 9a. Crane
equipment and attachment
equipment must be properly
dimensioned!
►Attachment equipment may
not be fastened to the motor’s
eyelets, unless being used as
additional safety against tilting
when top-heavy.
Refer to the order-specific documents for
weight specifications.
When using a crane to transport a pump, place
the attachment ropes securely around the
suction casing. If transporting a complete
pump unit, attach an additional rope to the
drive motor.
The attachment ropes must be placed around
the pump and pump unit so that they are
precisely balanced during lifting.
Make sure that the pump unit is transported
safely and in a stable position to and at the
place of installation. Make sure that it cannot
tip over due to top-heaviness.
Notice!
When receiving the pump, inspect it
for transport damages. Immediately
report any damages!
5.3 Preserving progressing cavity
pumps and placing them into
storage
5.3.1 Preserving
Notice!
Not necessary with stainless
materials.
Caution!
Improper preservation can result in
property damages!
►Properly apply a preservative
inside and outside.
•Select a preservative according to the type
and duration of storage (Preservatives,
page 10).
•Use preservatives according to
manufacturer specifications.
•Preserve all exposed metal parts inside
and outside.
Caution!
Use of improper preservatives may
damage the seal, universal joint
collar, and stator.
►Ensure that the seals, stator,
elastomer, universal joint
collars, and rotor screw are
preserved with silicone oil
only.
5.3.2 Storage
Caution!
Improper storage can result in
property damages!
►Properly preserve and store
the pump.
•Seal all openings with blank flanges, blank
plugs, or plastic covers.
•Ensure that the storage space meets the
following conditions:
-dry
-frost-free
-vibration-free
•Fully rotate the shaft once per month.
•When doing so, make sure the shaft, rotor,
and bearing move as well.

Transport, storage, and disposal
Preserving progressing cavity pumps and placing
them into storage
10
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Construction Type RG
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Notice!
The elastomer stator in the
progressing cavity pump is
particularly sensitive to the
elements (ozone, light,
temperature). Depending on the
pump size and type of storage, it
may be necessary to remove the
stator, package it in dark film and
store it within the temperature
range of -10 to +25 °C.
Discuss with factory.
5.3.3 Removing preservative
Notice!
Necessary only for preserved
pumps.
Warning!
Danger of food or water poisoning
by preservatives and cleaning
agents.
►Use only cleaning agents that
are compatible with the
pumped liquid (Cleaning
agents, page 11).
►Completely remove the
preservatives
Caution!
High water pressure or spray water
may damage the bearing!
►Do not clean the bearing
areas with spray water or
steam jets.
Caution!
Improper cleaning agents can
damage the universal joint collar,
stator, and seal!
►Make sure that the cleaning
agent does not attack the
universal joint collar, stator,
and seals.
•Internal preservatives can be removed by
rinsing the pump with the pumped liquid.
But, if contamination in the pumped liquid
is impermissible, the pump must be
disassembled and the metal parts cleaned
with an approved cleaning agent.
•Choose cleaning agents appropriate for
the area of usage (Cleaning agents,
page 11).
•Dispose of preservatives according to local
regulations.
•If storage time is greater than 12 months:
-Inspect all elastomers (stator,
round seal rings, shaft seals) for
shape elasticity and replace if
necessary.
-Replace elastomers made of EP
rubber (EPDM).
5.3.4 Preservatives
Notice!
Preservatives from Valvoline or
comparable are recommended.
Type of storage
Storage time
(months)
Internal
preservative
Replacement
(months) internal
External
preservative
Replacement
(months) external
In a closed,
dry, and
dust-free
area.
6-12 Tectyl
502-C-EH - Tectyl 846-K-19 -
>12 Tectyl
502-C-EH 24 Tectyl 846-K-19 36
Outdoors,
central
European
climate
6-12 Tectyl
502-C-EH 3 Tectyl 846-K-19 -
>12 Tectyl
502-C-EH 3 Tectyl 846-K-19 12
Outdoors,
tropical
climate,
aggressive
industrial
air, or near
the ocean.
6-12 Tectyl
502-C-EH 3 Tectyl 846-K-19 -
>12 Tectyl
502-C-EH 3 Tectyl 846-K-19 12
Tab. 5 Valvoline preservatives

Transport, storage, and disposal
Disposal
760.0003 GB - 151 999 BA-2011.04
Series AE.N
Construction Type RG
11
Reference to “Internal preservation” point from
Tab. 5, page 10.
Caution!
Use of improper preservatives may
damage the seal, universal joint
collar, and stator elastomer.
►Ensure that the seals,
universal joint collars, stator
elastomers, and rotor screw
are preserved with silicone oil
only.
5.3.5 Cleaning agent
Operational range Cleaning agent
Food and drinking
water Such as spirits, Ritzol 155,
highly alkaline soap base,
steam jets (for individual
parts only).
Miscellaneous Cleaning ether, cleaning
solvent, diesel fuel,
petroleum, alkaline cleaner
Tab. 6 Cleaning agents
5.4 Disposal
Plastic parts and elastomers can be conta-
minated by toxic or radioactive pumped liquids
in such a way that cleaning is not adequate.
Warning!
Danger of poisoning or
environmental damage by pumped
liquid or oil!
►Use personal protective
clothing when performing any
work on the pump.
►Before disposing of the pump:
Capture escaping liquid and oil.
Dispose of them separately
according to local regulations.
►Neutralize residual liquid in the
pump.
►Remove preservative 5.3
Preserving progressing cavity
pumps and placing them into
storage page 9.
►Remove plastic parts and
elastomers and dispose of
them according to local
regulations.
Dispose of pump according to local
regulations.

Installation and connection
Setting up the pump
12
Series AE.N
Construction Type RG
BA-2011.04 760.0003 GB - 151 999
6 Installation and connection
6.1 Setting up the pump
Pumps must be installed horizontally.
Warning!
Danger of burns and scalding!
To avoid burns and personal injury,
protective equipment according to
EN 809 must be provided at the site
of installation when the temperature
of pumped liquids exceeds 60 °C.
6.2 Foundation
The type of foundation depends on the size of
the pump and pump unit and conditions at the
site of installation.
Refer to our dimension sheets and unit
drawings for precise pump and unit
dimensions.
The foundation may take the form of a
concrete foundation or a weight-bearing frame
constructed of steel, for example.
Regardless of foundation type, the foundation
must be designed so that it can absorb the
weight of the pump unit along the entire
surface area.
6.2.1 Steel frame configuration
A steel frame must be designed so the entire
surface of the base plate contacts the frame
and can be fastened with screws or welded in
place.
Caution!
If the base plate is supported only
at isolated points, this will cause the
pump unit to sag in the center or
warp. This will affect alignment of
the pump unit and can lead to high
noise emissions and damage!
6.2.2 Characteristics of a concrete
foundation
The foundation must be horizontal, even, and
clean and fully absorb the foundation load.
A concrete foundation must be designed so
the entire base plate contacts the foundation
and can be fastened with suitable screws (refer
to unit drawings for connection dimensions).
Caution!
If the base plate is supported only
at isolated points, this will cause the
pump unit to sag in the center or
warp. This will affect alignment of
the pump unit and can lead to high
noise emissions and damage!
6.2.3 Fastening the pump unit to
the concrete foundation
►After aligning the pump unit on the
foundation, uniformly tighten the
attachment screws by incrementally
tightening each of the screws.
6.2.4 Characteristics of a concrete
foundation for cast base
plates
When building forms for the concrete
foundation, make sure that there will be
adequate space between the upper edge of
the completed foundation block and the lower
edge of the base plate for the purpose of
aligning the pump unit and packing with mortar
compound.
►After aligning the pump unit on the
foundation, uniformly tighten the
attachment screws by incrementally
tightening each of the screws.
►The cured concrete foundation must be
horizontal, even, and clean.
►Any oil present on the foundation must be
removed.
►Clean and blow with air the recessed
anchor holes for the foundation screws.
►Before bringing the pump unit into place,
roughen and clean the surface of the
concrete foundation in order to ensure
good adhesion between the foundation
block and mortar compound.
6.2.5 Mortaring the base plate
►After aligning the base plate on the
concrete foundation, use a non-shrinking
mortar compound to mortar the entire
length of the base plate. Mortar the anchor
holes with the foundation screws loosely in
place.
►Once the mortar compound has cured
around the base plate and in the anchor
holes, uniformly tighten the foundation
screws by incrementally tightening each
screw.
Notice!

Installation and connection
Base plate
760.0003 GB - 151 999 BA-2011.04
Series AE.N
Construction Type RG
13
Make sure that the entire length of
the base plate has support during
mortaring and packing of the mortar
compound. Tap the base plate to
detect any unfilled areas. Fill any
unfilled areas that are found!
6.3 Base plate
Fasten the base plate to the foundation without
residual tension.
Use a straightedge to detect any twisting of
the pump unit:
Fig. 3 Check for twisting
•Measure at the circumference of the
coupling at two levels, offset by 90°.
•Use the straightedge (1) to check the
light gap at the outer diameter:
Lay the straightedge over both halves
of the coupling.
Notice!
Couplings with a spacer piece
(spacer coupling) can also be
checked with a caliper.
•Loosen fastening screws at the foot of
the discharge casing (504) and the
shaft sealing housing (see sectional
drawings on page 43). After loosening
of the screws, the foot of the discharge
casing and the shaft sealing housing
may not be tilted, nor spring, nor be
under pressure.
•If major deviations are found, loosen
the base plate attachment and remove
the tension by refilling.
6.4 Coupling
Fine adjustment of the coupling:
Danger!
Life-threatening danger from
moving parts!
►Shut off the motor's power
supply and lock it in the off
position before all assembly
and maintenance tasks.
Caution!
Improper alignment of the coupling
will cause property damage!
►In the case of height, lateral,
or angular misalignment, align
the drive precisely with the
pump.
►For detailed information and
for special couplings: (
Manufacturer’s specifications).
Checking alignment of the coupling
Aids, tools, material:
•Feeler gauge
•Straightedge
•Caliper (option if coupling has spacer
piece)
•Other suitable tools, such as a laser
alignment device
Fig. 4 Check coupling alignment
1. Measure at the circumference of the
coupling at two levels, offset by 90°.
2. Use the straightedge (1) to check the
light gap at the outer diameter:

Installation and connection
Assembling pump and drive
14
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Construction Type RG
BA-2011.04 760.0003 GB - 151 999
•Lay the straightedge over both
halves of the coupling.
•If there is a light gap at the outer
diameter, align the drive using
metal shims.
3. Check size of gap with feeler
gauge (2):
•Permissible gap size (Unit
drawing).
•Use feeler gauge to measure gap
size (A) between two halves of
coupling.
•If impermissible gap size is found,
align the drive.
Fig. 5 Check lateral and height misalignment
4. Check lateral and height misalignment
with caliper:
•Perform measurement as shown.
•If lateral or height misalignment is
found, use metal shims to align
drive. Permissible axial or radial
deviation, measured on the front
side of the coupling or at the
coupling circumference: <0.05 mm.
Fig. 6 Check angular misalignment
5. Check angular misalignment with
caliper:
•Perform measurement as shown.
•If angular misalignment found: Align
drive
6.5 Assembling pump and drive
If the pump unit will be put together at the
place of installation, establish the coupling
connection as follows:
1. Apply a very thin layer of molybdenum
disulfide (such as Molykote) to the
ends of the pump and drive shaft;
insert keys.
2. Use a hoisting device to hoist the
pump and motor sides of the coupling
until the shaft end overlaps the
coupling hub. If a hoisting device is not
available, warming the halves of the
coupling to approx. 100 °C will make it
easier to slide the coupling halves.
Notice!
Be sure to remove the rubber
cushions first.
3. Use a threaded pin according to DIN
EN ISO 4029 to fasten the coupling
halves in the axial direction.
Caution!
When putting together the pump
and motor, gear motor and variable
gear, make sure that the coupling
halves are precisely aligned and
that the distance between the
coupling halves is maintained (refer
to Unit drawings and coupling
manufacturer’s specifications for
proper distance see
Section 6.4).
Warning!
Danger of being caught, wound,
drawn in and trapped.
Install safety guarding according to
DIN EN 809!
6.5.1 Space requirement for
maintenance and repair
Caution!
The pump must be accessible from
all sides in order to enable the
necessary visual inspections.