Fristam Pumpen FDS Series User manual

Original operating guide
Assembly instructions
Twin screw pump 
FDS series
Pump type:
Pump no.:

Copyrights
© Copyright 2016 FRISTAM Pumpen Schaumburg GmbH 
All rights reserved. The contents of this operating guide, including layout and images, are protected
by copyright and other laws protecting intellectual property. Disseminating or altering the content of
this operating guide is forbidden. Moreover, the content may not be copied, disseminated, altered or
made available to third parties for commercial purposes.
The original version of this operating guide is the German version.
Other language versions are translations of the original German operating guide.

3
Table of contents
1 Introduction............................................... 5
1.1 Foreword................................................................... 5
1.2 Manufacturer........................................................... 5
1.3 Delivery contents................................................... 5
1.4 Pump without motor (optional) ....................... 5
1.5 Documentation contents.................................... 5
1.6 Formatting conventions...................................... 5
2 Safety.......................................................... 6
2.1 Basic safety notices................................................ 6
2.2 Intended use............................................................ 6
2.3 Foreseeable incorrect use................................... 6
2.4 Pump-specific safety notices ............................. 6
2.5 Warning and notice signs ................................... 6
2.6 Noise emission........................................................ 7
2.7 Disposal ..................................................................... 7
3 Structure and function.............................. 7
3.1 Basic structure......................................................... 7
3.2 General remarks ..................................................... 8
3.3 Sizes ............................................................................ 8
3.4 Add-ons ..................................................................... 8
3.5 Type designation ................................................... 8
4 Transport.................................................... 9
4.1 Safety notices .......................................................... 9
4.2 Transport using forklift ........................................ 9
4.3 Transport by crane ................................................ 9
5 Storage ....................................................... 10
5.1 Storage conditions for the pump..................... 10
5.2 Long-term warehousing ..................................... 10
5.3 Recommissioning .................................................. 10
6 List .............................................................. 11
6.1 Safety notices .......................................................... 11
6.2 Installation site........................................................ 11
6.3 Reduction of noise and vibrations .................. 11
6.4 Attach pump ........................................................... 11
6.5 Align coupling ........................................................ 11
6.6 Install pipelines ...................................................... 11
6.7 Establish electrical connection......................... 12
6.8 Connect barrier or quench fluid (optional).. 12
6.9 Cleaning.................................................................... 13
7 Operation .................................................. 13
7.1 Safety notices.......................................................... 13
7.2 Commence operation.......................................... 13
7.3 Observe operation ................................................ 13
7.4 End operation......................................................... 14
7.5 Remove the pump from operation................. 14
8 Cleaning during operation ...................... 14
8.1 CIP method.............................................................. 14
8.2 SIP method .............................................................. 14
9 Faults ......................................................... 15
9.1 Safety notices.......................................................... 15
10 Maintenance ............................................. 15
10.1 Safety notices.......................................................... 15
10.2 Spare parts............................................................... 15
10.3 Check the barrier and quench fluid
(optional).................................................................. 15
10.4 Check the oil level ................................................. 15
10.5 Change oil ................................................................ 15
10.6 Lubricate motor bearings................................... 16
10.7 Replace shaft seal.................................................. 16
10.8 Dismantle pump head......................................... 16
10.9 Mount pump head................................................ 17
10.10 Replace shaft bearing ......................................... 17
10.11 Check gap dimensions ........................................ 17
11 Appendix 1 ................................................ 18

/ / FDS TWIN SCREW PUMPS / / /
4
11.1 Technical specifications....................................... 18
11.2 Maintenance intervals.......................................... 18
11.3 Fault table................................................................. 19
11.5 EC Declaration of Conformity............................ 21
11.6 EC Declaration of Incorporation....................... 21
12 Appendix 2 – Assembly instructions (optio-
nal) for pump with bare shaft...................22
12.1 Safety notice............................................................ 22
12.2 Application............................................................... 22
12.3 Nameplate................................................................ 22
12.4 Transport without motor .................................... 22
12.5 Installation site........................................................ 23
12.6 Mount pump ........................................................... 23

5
1Introduction
1.1 Foreword
This operating guide describes all sizes, shapes and designs of
the FDS twin screw pumps.
Please refer to the nameplate on your pump and to the “Or-
der documents” among the accompanying documents to see
what shape, size, design and add-ons apply to your pump.
1.2 Manufacturer
FRISTAM Pumpen Schaumburg GmbH
Kurt-A.-Körber-Chaussee 55
21033 Hamburg
GERMANY
Tel.: [phone]
E-mail: [email protected]
1.3 Delivery contents
The delivery consists of:
– Pump with (gear) motor (= pump aggregate),
optional: Delivery without motor,
– Pipe connection covers,
– Documentation,
–Fristam accessories if applicable,
– optional: Assembly set.
Check the delivery for completeness and any transport da-
mages. In the event of any issues, inform Fristam immedia-
tely.
1.4 Pump without motor (optional)
The pump can be supplied without a motor as an option. In this
case, read up through Chapter 3 “Structure and function” and
then continue with Chapter 12 “Appendix 2 – Assembly instruc-
tions (optional) for pump with bare shaft”, Page 22.
1.5 Documentation contents
The documentation consists of:
–this operating guide
– Appendix 1 with tables on maintenance, lubrication and
tightening torques,
– Appendix 2 with assembly instructions,
–accompanying documents
– order documents, (data sheet)
– supplier documentation (motor, coupling, etc.),
– documentation on Fristam accessories if applicable,
– certificates if applicable (material certificates, etc.),
– declaration of conformity or declaration of incorporati-
on.
1.6 Formatting conventions
Lists are indicated by dashes:
–Part1,
–Part2.
Instructions that need to be worked through in a specific order
are numbered consecutively:
1. Turn on unit.
2. Switch off unit.
Instructions that do not need to be worked through in a specific
order use triangles as a convention:
Action.
Action.
1.6.1 Safety notices
A safety notice with the signal word “Danger” alerts you to ha-
zards to human beings that will inevitably result in death or seri-
ous injury.
A safety notice with the signal word “Warning” alerts you to ha-
zards to human beings that may result in death or serious injury.
A safety notice with the signal word “Caution” alerts you to ha-
zards to human beings that may result in moderate or minor in-
jury.
A safety notice with the signal word “Attention” alerts you to the
risk of property damage.

/ / FDS TWIN SCREW PUMPS / / /
6
2 Safety
2.1 Basic safety notices
Read this operating guide all the way through before using
the pump and keep it available in the area where the pump
is used.
Observe the applicable national regulations in the operator
country and in-house work and safety regulations.
All works described here may only be carried out by quali-
fied personnel exercising due care and caution.
Risk of contamination: Observe statutory and in-house safe-
ty regulations when pumping hazardous pumped media.
2.2 Intended use
The standard version of the FDS twin screw pumps is designed
for use in the food industry, in the pharmaceutical and biotech-
nology sectors, and for CIP process engineering.
FDS twin screw pumps are intended for pumped media having
the maximum temperatures and pressures determined on the
basis of the pump design and size. This information is listed on
the order data sheet.
The pump’s delivery rate is preset. The position of the suction
and pressure port is indicated and is listed on the order data
sheet. FDS twin screw pumps are able to generate negative
pressure in the suction line.
Each pump is designed according to customer requirements.
The sealing materials have been selected for the pumped medi-
um in question.
The pump may only be operated under the conditions of use
defined in the order. See “Order documents”. If the operating
conditions should differ, please contact Fristam.
2.3 Foreseeable incorrect use
The standard version of the FDS twin screw pumps may not be
used in explosive atmospheres. Special Ex versions are available
for such conditions.
Pumped media for which the pump is not designed may destroy
the pump.
The presence of debris in the pumped medium may block and
destroy the pump.
This operating guide describes standard Fristam pump aggrega-
tes. In the event of exceptions and the installation of extras, the
operator is responsible for operation.
Conversions and modifications to the pump are only permitted
after consulting with Fristam.
2.4 Pump-specific safety notices
Unacceptable pressure range
Personal injury and property damage caused by bursting and le-
aks in the pump.
Comply with the pump’s pressure range. See data sheet.
Unacceptable temperature range
Personal injury and property damage caused by bursting and le-
aks in the pump.
Comply with the pump’s temperature range. See order data
sheet
Dry running
Property damage
Dry running must be avoided, in principle. If the pump is
equipped with a double-acting shaft seal, short-term dry
running/“resting” is possible, provided that the seals are rin-
sed. If the pump is equipped with a single-acting shaft seal,
even short-term dry running may cause damage.
Cold extinguishing water on heated pump
Property damage
When extinguishing, do not focus the extinguishing stream
directly on the pump.
Let the pump cool off as slowly as possible.
Hot device surface
Skin burns from touching the pump.
Check the temperature before touching the pump.
Only touch the pump with heat-resistant protective gloves.
Noise emission when pump is running
Permanent hearing damage. The A-weighted sound pressure le-
vel of the pump may be higher than 80 dB (A).
When in the vicinity of the running pump, always wear ear
protection.
Comply with local statutory regulations governing noise ex-
posure.
2.5 Warning and notice signs
Do not remove or alter the markings on the pump.
Faithfully restore markings on the pump that have been da-
maged or lost immediately.
2.5.1 Hot surface
Fig. 1 Safety marking: “Hot surface”

7
This marking indicates that parts may become hot as a result of
pump operation, or that hot pumped fluids may be pumped at
this point. Check the temperature before touching the pump.
The pump must only be touched while wearing suitable protec-
tive gloves.
2.5.2 Nameplate
Fig. 2 Nameplate
2.6 Noise emission
Noise emission when pump is running
Permanent hearing damage
Comply with local statutory regulations governing noise ex-
posure.
When using pumps for which a sound pressure level of grea-
ter than 80 dB (A) is indicated, wear hearing protection.
2.7 Disposal
2.7.1 Disposal of transport packaging
Take transport packaging to a recycling centre.
2.7.2 Disposal of lubricant
Grease and greasy objects are to be disposed of in an en-
vironmentally friendly manner in accordance with applicab-
le regulations.
2.7.3 Disposal of lubricating oil
Oil and oily objects are to be disposed of in an environmen-
tally friendly manner in accordance with applicable regula-
tions.
2.7.4 Disposal of pump
1. Dispose of hazardous and toxic residues in an environmen-
tally friendly manner and in accordance with applicable re-
gulations.
2. Clean the pump carefully.
3. Disassemble pump into the individual components.
4. Dispose of pump parts in an environmentally friendly man-
ner in accordance with applicable regulations.
2.7.5 Disposal of electrical and electronic waste
Dispose of electrical and electronic waste in accordance with
the applicable guidelines.
3 Structure and function
3.1 Basic structure
Fig. 3 Basic structure of the FDS pump aggregate
3.1.1 Pump with synchromesh gear (A)
Fig. 4 Basic structure of an FDS positive displacement pump
APump with synchromesh gear
BCoupling
CMotor/gear motor
1Pump cover
2Pump housing
B
A
C
1234 5 6

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8
3.1.2 Coupling (B)
The coupling connects the shaft from the motor to the drive
shaft (6) of the pump. The coupling transfers the drive torque of
the (gear) motor to the pump.
3.1.3 Motor/gear motor (C)
The drive is an electric motor with fixed or variable speed. It is
bolted to the base frame or foundation.
3.2 General remarks
The following versions are available as an option for all configu-
rations:
– single or double shaft seal
One of two seal types can be selected: Single shaft seal or
double shaft seal.
In the double shaft seal version, there are four additional
ports for the barrier fluid on the intermediate flange. These
ports are not depicted in the illustrations in this operating
guide; see Chapter 6.8.1 “Connect pipelines”, Page 12.
– horizontal or vertical pump connection,
– heating jacket
The pump can be equipped with a heating jacket on the
pump housing.
3.3 Sizes
3.4 Add-ons
FDS twin screw pumps may be equipped with the following
add-ons, among others:
– Lining
Stainless steel lining for the motor. The lining is attached to
the base frame,
– Domed feet
Domed feet on which to install the pump. Domed feet are
mounted on the base frame of the pump.
Additional add-ons are possible. Please contact Fristam if you
have any questions.
3.5 Type designation
Fig. 5 Type designation example
Note: If your pump is delivered without a motor (optional) begin
by reading Chapter 12 “Appendix 2 – Assembly instructions (optio-
nal) for pump with bare shaft”, Page 22.
3Intermediate flange
4Leakage chamber of the shaft seal
5Bearing bracket
6Drive shaft
FDS series
FDS 1
FDS 2
FDS 3
FDS 4
FDS 5
Table 1 Sizes
7Pump type
8Size
9Displacement device
10 Additional symbol 1
11 Additional symbol 2
(7) Type of pump
FDS Twin screw pump, self-priming
(8) Size
XNumberofsize
(9) Displacement device
X Number of the installed displacement device
(10) Additional symbol 1
Vvertical
S lateral
– no symbol means standard
(11) Additional symbol 2
Lextended
7910811
FDS 3 - 3 V L

9
4Transport
The pump may only be transported by trained personnel.
The pump aggregate may be transported by forklift or by crane.
4.1 Safety notices
Falling or unsecured components
Severe bruises.
Always wear safety shoes during all transport work.
Incorrect transport position of the pump
Leakage of corrosive, toxic or contaminating fluids. Personal in-
jury and property damage caused by contamination.
Always transport pump in the installation position.
Open, unsealed pipe connections
Property damage caused by contaminants, impacts or moisture
in the pump.
Do not remove the pipe connection covers until immedia-
tely prior to connecting to the pipes.
4.2 Transport using forklift
Unsecured components
Serious injuries, bruising of limbs, property damage.
Secure the pump against toppling prior to transport. Secure
onto the pallet using transport straps or bolt the pump onto
the pallet.
Preparation
Check whether the pump is adequately secured on the pal-
let. For instance using straps, see Fig. 6 “Transport by forklift”,
Page 9.
Take into account the weight of the pump when selecting
the means of transport. For information on the weight of the
pump see the pump nameplate and refer to “Order docu-
ments” in the accompanying documents.
Procedure
1. Pick up the pallet using the forklift.
2. Slowly and smoothly transport the pallet to the destination
and deposit there.
Fig. 6 Transport by forklift
4.3 Transport by crane
Falling parts
Death by crushing, serious bruising of limbs, property damage.
Use only appropriate means of transport and lifting tackle.
For information on the weight of the pump see the pump
nameplate and refer to “Order documents” in the accompa-
nying documents.
Do not transport the pump aggregate by the eyebolts on
the motor or on the pump, as these eyebolts are not desi-
gned to bear the full weight of the pump aggregate.
Do not leave the pump in the raised position longer than
necessary.
Make sure that there is no one in the area below the pump.
Vibrating parts
Bruising and serious injury.
Approach the pump smoothly with the crane and come to a
smooth stop.
Make sure that there is no one in the danger zone of the
pump.
Aids
Lifting tackle: tested round slings in accordance with
DIN EN1492-1 and 1492-2.
Preparation
Remove transport safety devices.
Procedure
1. Warning: Damage to and tearing of the round sling. Death
by crushing, serious bruising, property damage.
Do not let the round sling come into contact with sharp
corners and edges.
Place the round sling around the gear motor, see Fig. 7
“Transport with round sling”, Page 10.
2. Put the other end of the round sling around the pump
housing, see Fig. 7 “Transport with round sling”, Page 10.
3. Double shaft seal:

/ / FDS TWIN SCREW PUMPS / / /
10
Attention: The round sling presses against the barrier water
tubes. Damage to double shaft seal.
Circumvent the barrier water tubes with the round sling.
4. Walk both slings to the crane hook, twist and place on the
hook in such a way that the strap cannot slip off the crane
hook.
5. Arrange the centre of gravity to make sure that the pump is
lifted in the horizontal position.
6. Lift the pump.
.
Fig. 7 Transport with round sling
5Storage
5.1 Storage conditions for the pump
Store the pump as follows:
– dry, at low humidity,
– protected against frost and heat, preferably at 20°C to 25°C,
– ventilated,
– dust-free.
All of the pump’s moving parts must be turned every three
months.
5.2 Long-term warehousing
The following must be kept in mind if the pump is being stored
for more than six months:
before placing the pump in storage, completely disassemble
the shaft seals and store separately.
In this regard please refer to Chapter 5.2.1 “Storage of elasto-
mers”, Page 10.
Fill gearbox with oil up to the upper edge of the gear wheel.
5.2.1 Storage of elastomers
Store elastomers as follows:
– storage temperature between +5°C and +20°C,
– relative humidity below 70%,
– no direct sunlight,
– deformation-free storage.
5.3 Recommissioning
After warehousing, the seals, bearings and oil level must be
checked before recommissioning.

11
6List
6.1 Safety notices
Falling or unsecured components
Severe bruises.
Always wear safety shoes during all installation work.
Incomplete, unstable mounting
Severe bruises, damage to property.
Tighten screws with the specified tightening torque, see
Chapter 11.1.1 “Tightening torques”, Page 18.
Use a torque wrench or impact wrench with adjustable tor-
que.
Vibrations during domed footinstallation
Damage to plant and pump.
Use domed foot plate.
6.2 Installation site
The installation site for pumps with standard equipment must
satisfy the following conditions:
– Non-explosive atmosphere.
– Dust-free environment.
– Ambient temperature: –20°C to +40°C.
– Values for the humidity and salinity of ambient air are indi-
cated in the motor supplier documentation in the accompa-
nying documents.
– A foundation sufficiently dimensioned for the weight of the
pump.
– Horizontal and flat installation surface. Strength of installati-
on surface is sufficient for the mass of the pump.
– Refer to the motor supplier documentation for installation
clearances.
– Adequate space for maintenance.
– Adequate ventilation for motor cooling.
6.3 Reduction of noise and vibrations
6.3.1 Primary measures
– Operate the pump in the optimal working range.
Operate the pump without cavitation (see Chapter 6.6
“Install pipelines”, Page 11).
– Isolate suction and pressure line from vibrations.
Support the lines.
Align the lines.
Insert elements for vibration damping.
6.3.2 Secondary measures
Implement structural measures such as:
– Sound insulation cover,
– Enclosure.
6.4 Attach pump
6.4.1 Pump with base frame
Screw pump onto the foundation through the base frame.
6.4.2 Pump with base frame on domed feet (optional)
Install the pump on the domed feet and align.
6.4.3 Chassis (optional)
1. Set up the pump at the installation site. Use the locks on the
casters (if present) or fix the chassis using chocks.
2. Ground the chassis in order to dissipate electrostatic char-
ges.
3. Lay the hose in such a way that it cannot be damaged.
6.5 Align coupling
1. Check centre offset and angular offset of the shafts.
Fig. 8 Centre offset
Fig. 9 Angular offset
2. Re-align or shim the shafts as needed. See the enclosed cou-
pling supplier documentation for more precise information.
6.6 Install pipelines
Lay and connect pipelines as follows:
Keep pipeline resistance as low as possible: Avoid the
unnecessary installation of valves, bends and abrupt transi-
tions.

/ / FDS TWIN SCREW PUMPS / / /
12
Fig. 10 Pipeline crossings
Design the pipeline cross-section in such a way that no
unnecessary pressure losses occur, or cavitation in the sucti-
on or inlet area.
Marking: if possible, fit shut-off valves in the suction and
pressure line Pay attention to correct connection (suction
side and pressure side). The housing is provided with corres-
ponding markings.
Design the suction lines to be as short as possible.
Lay the suction lines horizontally or continuously sloping in
the direction of the pump aggregate. Make sure there are no
air cushions or sinks in the pipelines.
Fig. 11 Air cushions in the pipeline
Fig. 12 Sinks in the pipeline
Design pipe connections as a function of: 
pressure, temperature and nature of the pumped medium.
Lay and connect the pipelines in such a way that no warping
occurs on the pump.
Affix pipelines to ceilings, walls or ground using pipe
clamps.
Align the pipelines flush with the pump connections using
an angle.
6.7 Establish electrical connection
Electrostatic charge
Electric shock.
Ground pipelines and the pump so that electrostatic charges
can be dissipated.
The electrical connection may only be carried out by a qualified
electrician.
Procedure
1. Observe the connection values on the motor nameplate.
The specified voltage must not be exceeded.
2. Only connect the motor to fused electrical circuits in order
to prevent excessive current consumption.
3. Connect the motor in accordance with the wiring diagram in
the motor terminal box.
4. Protect cable penetrations against the ingress of moisture.
5. Turn the motor on for 2 to 3 seconds. During this time, check
the direction of rotation of the motor fan impeller.
6. If the direction of rotation is wrong, reverse the polarity as nee-
ded.
6.8 Connect barrier or quench fluid (optional)
For versions with a double shaft seal, the seal chamber of the
shaft seal must be rinsed with barrier fluid or quench fluid.
Use a suitable medium as barrier fluid or quench fluid.
See Appendix - Data sheet
6.8.1 Connect pipelines
A
A
G

13
1. Fit the feed line below the shaft seal.
2. Fit the drain line above the shaft seal.
6.9 Cleaning
Only use cleaning agents that meet the technical hygiene stan-
dards for the respective pumped medium.
1. Before closing the pump, make sure that there are no for-
eign substances inside the pump and pipelines.
2. Close the pump.
3. Connect the pipelines.
4. Prior to first use, clean the pump and pipeline system com-
pletely.
7Operation
7.1 Safety notices
Closed valve in the pressure line
Serious personal injury and property damage caused by a
bursting of the system due to very high pressure build-up.
Both before switching on and during operation, make sure
that all of the pressure line’s valves are open.
Provide a bypass or other approved safety devices for pres-
sure peaks, as this is a positive displacement pump.
Closed valve in the suction line
Damage to the shaft seal due to dry running of the pump.
Both before switching on and during operation, make sure
that all of the suction line’s valves are open.
No pumped medium inside the pump
Dry running of the pump. Damage to the shaft seal.
For single shaft seal pumps, make sure that there is always
pumped medium inside the pump both prior to and during
operation.
7.2 Commence operation
Double shaft seal: 
Loss of barrier fluid
Damage to the shaft seal.
During operation, make sure that:
– Barrier fluid with sufficient pressure is flowing through
the double shaft seal (see information on the enclosed
“Data sheet”),
– The temperature of the barrier fluid is maintained at T <
70°C.
1. Open the valve in the suction line.
2. Open the valve in the pressure line.
3. Fill the pump and suction line with pumped medium to the
upper edge of the pump. Allow any air pockets that may be
present to escape.
4. Only for pumps with barrier or quench fluid:
Verify the necessary barrier pressure. For maximum barrier
pressure, please refer to the “Data sheet”in the enclosed do-
cuments.
5. Switch on the motor.
7.3 Observe operation
While the pump is running, observe the following safety notices:
Debris in the pumped medium
Blocking of displacement device and shearing of the shaft.
Eliminate debris in the pumped medium.
– Provide a current limiting device on the gear motor.
Sudden closing of the valves in the pressure line
Damage to the system possible through excess pressure.
During operation do not close the valve in the pressure line
suddenly or for an extended period of time.
Inlet
A
Outlet
BC D E F G
FDS 1
FDS 2 G¼" (m/f) G¼" (m/f) 7.5° 42 12 Ø8 310
FDS 3 G¼" (m/f) G¼" (m/f) 7.5° 50.5 12 Ø10 375.5
FDS 4
Table 2
A-A
optional (4x)
B
A
C
C
DD
E
E
F
F

/ / FDS TWIN SCREW PUMPS / / /
14
Sudden cooling of the pump
Stress cracks in the pump.
– Do not abruptly cool the pump.
Cavitation and dry running of the pump
Damage to the shaft seal.
– During operation, make sure that the suction side valves are
open.
7.4 End operation
1. Switch off the motor.
2. Close the valve in the suction line in order to prevent dry
running of the pump.
3. Close valve in the pressure line.
7.5 Remove the pump from operation
1. Switch off the motor.
2. Close the valve in the suction line.
3. Close valve in the pressure line.
4. Disconnect the pump from the power source.
5. Drain the pump.
6. Clean the pump as described in Chapter 6.9 “Cleaning”,
Page 13.
7. Dry the pump.
8. Protect the interior of the pump against moisture, for instan-
ce using silica gel.
9. Fit caps over the pipe connections in order to prevent dirt
and debris from entering.
10. For additional steps please refer to Chapter 5 “Storage”, Page 10.
8 Cleaning during operation
8.1 CIP method
The FDS twin screw pumps are suitable for the CIP (Cleaning In
Place) method. Observe the following indicative values during
the CIP process:
Example cleaning process
1. Pre-rinse with water.
2. Caustic flushing with sodium hydroxide (NaOH, see Table 3
“CIP cleaning”, Page 14).
3. Perform an intermediate water rinse.
4. Acid flushing with nitric acid (HNO3, see Table 3 “CIP clea-
ning”, Page 14).
5. Final rinse with water.
The differential pressure of the pump should be 2 to 3 bar, so
that adequate flow rates are achieved in the pump.
Please contact Fristam if the values should deviate.
8.2 SIP method
Dry running of the pump with steam
Damage to the shaft seal.
When steam is flowing through the pipes, make sure that
the pump is switched off.
Slow rotation with the shaft is possible if the pump has a
double shaft seal (<300 1/min)
FDS twin screw pumps are only suitable for the SIP (Sterilisation
In Place) method in consultation with Fristam.
Suitability depends on the choice of elastomers.
The maximum process temperature is 145°C.
Temperatures in ATEX may differ; please refer to the ATEX ope-
rating instructions “Temperature configuration limit”.
Medium Process temperature [°C]
NaOH (approx. 1% to 2%) 80 to 85
HNO3(approx. 1%) 60 to 65
Table 3 CIP cleaning

15
9Faults
Please refer to Chapter 11.3 “Fault table”, Page 19 with regard to
faults, possible causes and remedies.
9.1 Safety notices
Hot device surface
Skin burns from touching the pump. The pump may become
very hot when conveying hot pumped media.
Before undertaking work on pump, allow the pump to cool
off completely.
Check the temperature before touching.
Only touch the pump with heat-resistant protective gloves.
10 Maintenance
Please refer to Chapter 11.2 “Maintenance intervals”, Page 18 re-
garding maintenance intervals.
10.1 Safety notices
Rotating parts
Personal injury and property damage.
Before working on the pump, always switch off the pump’s
motor and secure against reactivation.
Falling or unsecured components
Severe bruises.
Always wear safety shoes during all maintenance work.
Uncontrolled escape of liquids
Personal injury and property damage caused by chemical burns,
poisoning or contamination.
Before performing maintenance and cleaning work on the
pump:
Close the suction and discharge valves upstream and
downstream of the pump.
Double shaft seal: Shut the barrier or quench fluid line.
Completely drain the pump housing before opening the
pump.
Sudden cooling of the pump
Stress cracks in the pump.
Do not abruptly cool the pump.
Using hard screwdriving tools
Scratching of milled surfaces.
Use a copper insert for socket wrenches on milled surfaces.
10.2 Spare parts
Using spare parts not approved by Fristam may result in serious
personal injury and property damage. Please contact Fristam for
any questions regarding approved spare parts.
Fristam maintains a record of all pumps delivered. The following
information is required when ordering spare parts:
1. Serial number of the pump: refer to the nameplate or the
rim on the pump.
2. For designations of spare parts and materials, please refer to
“Order documents” in the accompanying documents.
10.3 Check the barrier and quench fluid (optio-
nal)
For pumps that have been equipped for “barrier fluid” or
“quench fluid”, the quench fluid pressure must be checked. For
maintenance intervals refer to Table 5 on page 18.
Check the barrier fluid pressure and compare to the speci-
fied value.
For the specified value please refer to the “Data sheet” in the
“Order documents”. The “Order documents” are enclosed with
this operating guide.
A hot pumped medium and operation of the pump cause the
barrier fluid to become heated.
Make sure that the temperature of the barrier fluid is main-
tained at T < 70°C during operation.
10.4 Check the oil level
This check is performed via an oil level gauge (14) located on
the back of the closing cap.
For maintenance intervals refer to Table 5 on page 18.
10.5 Change oil
Change the oil regularly on the FDS twin screw pumps. For
maintenance intervals refer to Table 5 on page 18.
Maintenance intervals
In general, change the oil once each year or every 4000 opera-
ting hours.
In extreme operating conditions, such as high humidity, an ag-
gressive environment, high temperature fluctuations, etc., we
recommend changing the oil every 2000 operating hours.

/ / FDS TWIN SCREW PUMPS / / /
16
Fig. 13 Oil level and oil change
Procedure
1. Switch on the engine and let it run until the normal opera-
ting temperature is reached.
2. Switch off the motor and secure it against reactivation.
3. Place an appropriately sized oil pan below the locking screw
(13).
4. Caution! Risk of burns from hot oil.
Wear heat- and oil-resistant protective gloves.
Loosen the bleed screw (12).
5. Loosen and remove the locking screw (13).
6. Drain the oil completely and dispose of it in accordance with
local regulations.
7. Clean the bleed screw and seals.
8. Fit the locking screw and bleed screw with the appropriate
seals.
9. Add new oil, in so doing checking the oil level using the oil
level gauge (14).
10.6 Lubricate motor bearings
Lubricate the motor bearings in accordance with the gear
motor manufacturer’s specifications. Please refer to “Sup-
plier documentation” in the accompanying documents.
10.7 Replace shaft seal
Replace the shaft seal if:
– Pumped medium, barrier fluid or quench fluid is leaking out
of the pump on the atmospheric side,
– Barrier fluid or quenching fluid is leaking into the pumped
medium.
Procedure at a glance
1. Dismantle the pump housing, 
see Chapter 10.8 “Dismantle pump head”, Page 16.
2. Replace shaft seal, 
see Chapter 10.9.2 “Installation of the shaft seal”, Page 17.
Pre-mount the pump housing.
Install the shaft seal.
3. Mount the pump housing.
4. Mount the displacement device.
5. Close the pump cover.
The exact procedure is described in the following chapters.
10.8 Dismantle pump head
10.8.1 Dismantle pump housing and feed screws
Preparation
1. Before dismantling, refer to the enclosed “data sheet” to de-
termine which type of shaft seal the pump has.
2. Switch off the motor and secure it against reactivation.
3. Close valve in the pressure line.
4. Close the valve in the suction line.
5. Double shaft seal: Shut the barrier or quench fluid line.
6. Drain the pump completely.
7. Loosen the suction and pressure connections.
Procedure
Fig. 14 Dismantle the pump housing with cover and the feed screws
1. Loosen the screws (19) for the pump housing attachment.
2. Remove the pump housing (16) with cover (15) .
3. Warning: Rotating machine parts. Severe bruises inflicted
on hand.
Block the feed screws (18) with an aluminium or plastic
wedge.
Screw off the feed screw attachment (17) with the asso-
ciated sealing rings (clockwise thread).
4. Remove the feed screws (18) from the drive shaft and the
driven shaft.
10.8.2 Dismantle the shaft seal
The pump may be supplied with a single or double–acting shaft
seal (see data sheet).
12 Bleed screw
13 Locking screw
14 Oil level gauge
12
14
13
17
15 18
16
19
20
21

17
1. Loosen the fastening screws (20) for the fixing plate (21).
2. Pull out the fixing plates.
3. Remove rotating units from the shafts.
4. Pull stationary units out of the intermediate flange.
10.9 Mount pump head
Pump assembly is dependent on the specific size and shape of
the pump, and on the given shaft seal. The type of shaft seal
provided is indicated on the “Data sheet”.
Wrong elastomers
Pump leakage.
Make sure that the elastomers are suited to the nature of the
pumped medium. Refer to the “Data sheet”.
Preparation
Clean all pump parts. Check for damage and accuracy of fit.
Rework or replace pump parts as needed.
Reassemble carefully under clean conditions. The seals can
easily be damaged.
In order to reduce friction, wet the secondary seals and sli-
ding surfaces with water, alcohol or silicone grease.
Clean the sealing surfaces of the mechanical seals with grea-
se-loosening cleaning agent, for instance “OKS 2610 Univer-
salreiniger”. After that, do not allow the sealing surfaces to
come into contact with oil or grease, and do not touch them
with your fingers.
Tip: The bonding compound “Euro Lock A64.80” is suitable for
gluing bearings and bushings in place.
Tip: The bonding compound “Euro Lock A24.10” is suitable for
gluing grub screws in place.
10.9.1 Observe markings
The feed screws must not be mixed up under any circumstan-
ces. They are assigned to the drive shaft or driven shaft, and
each have been marked with punches.
Note the markings before installing feed screws:
– one frontal punch for the drive shaft,
– two frontal punches for driven shaft.
10.9.2 Installation of the shaft seal
1. Reinsert the shaft seal into the intermediate flange in accor-
dance with the sectional drawing (anti-torsion groove exact-
ly lateral).
2. Reinsert the fixing plates (let them snap into place) and fix
using the screws.
3. Slide rotating parts onto the shafts.
10.9.3 Mount the pump housing and feed screws
1. Attention: Feed screws are assigned either to the drive shaft
or the driven shaft. See Chapter 10.9.1 “Observe markings”,
Page 17.
2. Push feed screws onto the shafts.
3. Warning: Rotating machine parts. Severe bruises inflicted
on hand.
Block the feed screws with an aluminium or plastic wed-
ge.
4. Tighten the feed screw using the specified tightening tor-
que. Please refer to Table 4 “Tightening torques for feed
screw”, Page 17.
5. Place the housing with cover onto the pump and tighten the
screws.
10.9.4 Close the pump
1. Provide the pump cover with an O-seal.
2. Slide the pump cover onto the pump housing.
3. Screw the pump cover onto the pump housing with nuts
and washers.
10.10 Replace shaft bearing
Contact Fristam.
10.11 Check gap dimensions
Contact Fristam.
Size Thread Tightening torque [Nm] ± 15%
FDS1 M12 60
FDS2 M16 120
FDS3 M20 160
FDS4 M24 200
FDS5 M24 240
Table 4 Tightening torques for feed screw

/ / FDS TWIN SCREW PUMPS / / /
18
11 Appendix 1
11.1 Technical specifications
11.1.1 Tightening torques
Tightening torque for screws and nuts ± 15%
Material: Steel, grade 8.8
Material: Steel, grade 10.9
Material: Stainless steel, class 70
Material: Stainless steel, grade 80
11.2 Maintenance intervals
Thread M6 M8 M10 M12 M16 M20 M24
Tightening torque
[Nm]
7 18 35 60 148 254 -
Thread M6 M8 M10 M12 M16 M20 M24
Tightening torque
[Nm]
11 26 51 89 218 361 -
Thread M6 M8 M10 M12 M16 M20 M24
Tightening torque
[Nm]
7 18 36 63 143 262 424
Thread M6 M8 M10 M12 M16 M20 M24
Tightening torque
[Nm]
10 24 48 84 191 351 568
Interval Shape Maintenance activity Chapter
Daily All Check the oil level See Chapter 10.4 “Check the oil level”, Page 15
Daily “Barrier and quench fluid” option Check barrier or quench fluid See Chapter 10.3 “Check the barrier and quench
fluid (optional)”, Page 15
2000 h All, in extreme operating conditions Oil change See Chapter 10.5 “Change oil”, Page 15
4000 h All, in normal conditions Oil change See Chapter 10.5 “Change oil”, Page 15
As needed All Replace shaft seal See Chapter 10.7 “Replace shaft seal”, Page 16
As needed All Replace coupling/coupling spider
As needed All Change engine
According to
manufacturer
instructions
All Lubricate the motor bearing;
for further motor maintenance intervals refer
to the motor supplier documentation.
See Chapter 10.6 “Lubricate motor bearings”,
Page 16
Table 5 Maintenance intervals

19
11.3 Fault table
Issue Possible cause Remedy
Pump does not pump or pumps irregularly Pump interior not filled completely with fluid;
discharge valve closed
Fill the pump interior with fluid;
Open the discharge valve
Blocked or clogged suction line Open or clean the suction line
Pump with geodetic suction head1: Liquid
drops during standstill and housing runs idle
Install foot valve in the suction line
Suction line leaky; seal on the pump cover is leaky
and draws air
Seal the suction line; replace the cover seal
Air pocket in the suction line Lay the suction line with continuously rising ele-
vation and with few diversions
Pump is blocked; debris in pump Clean the inside of the pump; visual inspection;
consult Fristam
Viscosity of the pumped medium is too high;
not able to flow, too viscous
Consult Fristam
Coupling penetrated due to previous
overloading
Consult Fristam
Delivery rate too great Oversized pump Consult Fristam
Speed too high Decrease speed
Delivery rate too low, pump head too low Pump selected is too small; motor speed too low
due to incorrect frequency
Consult Fristam;
Connect in accordance with the motor nameplate
Suction line leaky and draws air Fix leaks
Viscosity of the pumped medium is too high (too
viscous);
possible conversion to integrate a heating system;
consult Fristam
Wear on the displacement device; gap dimension
too large
Repair/replacement
Incorrect direction of rotation Carry out pipe and electrical connections properly
Metallic noise Debris inside the pump Dismantle, assess, repair as needed
Mechanical start-up of the feed screws;
Feed screw nut is loose
Dismantle, rework,
Correct slackness setting, tighten with tightening
torque, replace
Excessive wear on bearings and gears wheels due
to overloading or insufficient lubrication
Dismantle, assess, repair
Regular maintenance; lubricant service
Speed too high Use motor with frequency converter;
Consult Fristam
Pump running dry; shaft seal running dry Supply pumped medium immediately; supply
barrier water immediately
Flow noise Operation in load range Adjust operating point of the configuration
Flow losses in the suction line too great Increase the size of nominal widths,
Rule out throttling
Cavitation Check condition for NPSH calculation; see
Chapter 6.6 “Install pipelines”, Page 11;
Consult Fristam
Vibrations Dead weight and hydraulic forces of the pipelines
are putting strain on the pump.
Support the pipelines in such a way that the
pump is not subjected to strain; integrate vibra-
tion dampers as needed; make sure pressure
shocks do not reach the pump
Incorrect alignment of coupling Align the coupling in accordance with the cou-
pling manufacturer’s specifications
Excessive heating of the pump
shaft bearing and drive gear
Bearing damage Dismantle, replace bearing
Lack of lubricant Replace lubricant; 
Regular maintenance, see Table 5 on page 18, or
replenish
Incorrect alignment of coupling Align the coupling in accordance with the cou-
pling manufacturer’s specifications
Table 6 Fault table

/ / FDS TWIN SCREW PUMPS / / /
20
11.4 Numerical code
The numerical code refers to the enclosed “sectional drawings ”. The part numbers correspond to DIN 24250.
Motor current consumption too high Resistance in the pressure line too high; (delivery
rate too low)
Increase nominal width of the pressure line;
reduce
Viscosity and/or density of the pumped medium
too high
Consult Fristam
Massive damage to the pump shaft bearing or to
the gear motor
Dismantle and assess;
Consult Fristam
Leak on the shaft seal Mechanical damage or wear on the shaft seal Replace mechanical seal and radial shaft seal,
including all secondary seals; consider material
changeover; consult Fristam
Dry running of the shaft seal; suction head too
high; pumped medium temperature too high
Reduce the geodetic suction head1; use a double
shaft seal; consult Fristam
Barrier or rinse water pressure too high Adjust using throttle valve and pressure gauge
Materials of the shaft seal not chemically resistant
to the pumped medium; media temperature too
high
Consult Fristam;
Change over to cooling or double shaft seal
Barrier or rinse water pressure too low; barrier
water tubes are clogged; shaft seal is encrusted or
damaged;
Adjust barrier water inflow and outflow; clean the
barrier water tubes; replace the shaft seal
Barrier water contaminated or too hot Use drinking quality water at a maximum of 70°C
1The “geodetic head” is the vertical distance between the surface of the suction-side fluid level and the centre of the pump-pipe connec-
tions.
Issue Possible cause Remedy
Table 6 Fault table
Item Designation
101 Pump housing
113 Intermediate flange
160 Cover
161 Gear housing cover
182 Pump base
213 Drive shaft
223 Driven shaft
232 Feed screw right
233 Feed screw left
320 Angular contact ball bearing
325 Needle roller bearing
350 Bearing housing
360 Bearing cap
365 Closing cap
410 Profile seal
411 Sealing ring
412 O-seal
421 Radial seal
433 Mechanical seal
490 Mechanical seal fixing plate
515 Clamping ring
540 Gear wheel bushing
552 Conical spring washer
554 Washer
562 Cylindrical pin
642 Oil level gauge
Item Designation
872 Gear wheel
901 Hex bolt
902 Stud screw
903 Locking screw
913 Bleed screw
914 Allen screw
922 Feed screw nut
923 Bearing nut
930 Safety catch
931 Locking plate
932 Lock ring
940 Feather key
Item Designation