Maier novasys DP Series User manual

Operating Instructions Maier Rotary Joints
Series DP B-DP_en - Version 7– 16.02.2011
Christian Maier GmbH & Co. KG Maschinenfabrik
Würzburger Str. 67-69 Postfach 16 09
D-89520 Heidenheim D-89506 Heidenheim
[phone]; [phone]; vkd@ maier-heidenheim.de; www.maier-heidenheim.de

Operating Instructions Maier Rotary Joints
Series DP B-DP_en -Version 4 – 14.02.2011
Keep these instructions for future reference! 1
Contents
1Safety ..............................................................................................................................................................................2
2Design and function .........................................................................................................................................................3
3Information on design and mounting................................................................................................................................4
4Transport und Lagerung ..................................................................................................................................................4
5Mounting..........................................................................................................................................................................5
6Operation.........................................................................................................................................................................7
7Maintenance ....................................................................................................................................................................8
Christian Maier GmbH & Co. KG reserves the copyright to this manual. The instructions, information and illus-
trations contained in this manual may not be copied in any way, neither partially nor completely. Neither may the
instructions, information and illustrations be disclosed to third parties nor used to create competing products,
systems or facilities or assist in such activities in any way.

Operating Instructions Maier Rotary Joints
Series DP B-DP_en -Version 4 – 14.02.2011
Keep these instructions for future reference! 2
1. Safety
Application
Maier rotary joints may only be used as fittings to connect pressurized pipes carrying liquids to rotating
pressure systems. Such rotating pressure systems are, for example, rollers through which flow liquids for
cooling or heating purposes. Series DP rotary joints are primarily used for water. Series DP … - 800 is
available for usage with thermal oil. Other media are possible - please contact the manufacturer for de-
tails. Please refer to the section "Specifications and Spare Parts" for details on approved media and
their qualities/properties. These values are binding for the application.
Never modify the rotary joint or tamper with it in any way as this may cause dangers. Install, operate and
maintain the rotary joint only as described in these operating instructions. We shall not be liable for any
damages or plant interruptions whatsoever resulting from failure to observe these operating instructions.
These operating instructions do not contain all information important for the safe operation of the rotary
joint. Also observe all pertinent local and national regulations and legislation concerning workplace safety
and prevention of accidents.
Use only genuine or Maier-approved spare parts (standard norm parts). If you use other parts, this may
have adverse effects on the safety of the rotary joint.
1.1 Requirements concerning installation and maintenance staff as well as operators
Only staff that has read and fully understood these operating instructions and that is fully aware of the dan-
gers resulting from the rotary joint as well as the appropriate safety measures may work with Maier rotary
joints. Such staff must have at least the knowledge of a trained locksmith or industrial mechanic who has
experience with pressurized components.
1.2 Dangers
Warning!
If you touch hot parts or come into contact with hot liquids escaping under high
pressure, this may result in dangerous burns.
Mount a protective hood to the rotary joint in order to prevent persons from di-
rectly coming into contact with hot parts and to safely retain escaping medium.
Warning!
If the rotary joint blocks and rotates along with the roller, the hoses may be torn off
so that hot liquids can escape under high pressure.
Always observe the design and mounting information in chapter 3.
Monitor the rotary joint by means of a torque sensor or a vibration pickup.
Ensure that the rotary joint is regularly maintained as per chapter 7
1.3 Safety precautions
Always observe the following safety precautions for the operation of the rotary joint:
DP rotary joints that are operated at temperatures of more than 80°C (176°F) must be relubricated (see
7.2 on page 8).

Operating Instructions Maier Rotary Joints
Series DP B-DP_en -Version 4 – 14.02.2011
Keep these instructions for future reference! 3
2 Design and function
2.1 Function and components
Maier rotary joints are fittings used to connect pressurized pipes to rotating
pressure systems. Such rotating pressure systems are, for example, rollers
through which flow liquids, gases or steam for cooling or heating purposes.
Housing connections:
The connection to the stationary pressurized system is made by the station-
ary part of the rotary joint – the housing or the angle piece. Different rotary
joint versions are available:
Mono version: housing with one connection for supplying or removing the
medium to or from the rotating pressure system (version 1). DP rotary joints
are always delivered as mono version. Angle pieces must be used for
duo versions.
Duo version: rotary joint DP and angle piece for supplying and removing the
medium to and from the rotating pressure system. The second channel is
formed by an inner pipe that is centered in the center axis of the rotating
part.
The design of the inner pipe differs in terms of the following versions:
Stationary inner pipe (version 2): The inner pipe is screwed into the an-
gle piece (standard version always with right-hand thread).
Rotating inner pipe supported in angle piece
(version PR 2): The inner pipe is supported by the stationary angle
piece. There is wear at the bearing point.
Stationary inner pipe with floating bearing in O ring and anti-rotation
lock by means of screw (version PO 2): The inner pipe is held in the
angle piece by means of an O ring. A screw prevents it from rotating.
There is wear at the bearing point.
This also applies to series -800 with the difference, however, that the duo
version has an additional Viton O ring between angle piece and housing for
sealing purposes.
Rotor connections:
The connection to the rotating pressurized system is made by the rotating
part of the rotary joint – the rotor. The rotor is mounted to the rotating pres-
sure system (e.g. a roller) by means of a right-hand or left-hand thread R / L,
flange K (DN 40 (1½″) and 50 (2″)) or a fixed flange F (DN 40 (1½″) and
50 (2″)). The system is sealed by means of a sealing cone, flat packing or
an O ring.
Please refer to our catalog and the corresponding outline drawing for further
information.

Operating Instructions Maier Rotary Joints
Series DP B-DP_en -Version 4 – 14.02.2011
Keep these instructions for future reference! 4
3 Information on design and mounting
Attention!
Damage to components due to vibration and heat expansion.
Use only flexible hoses to connect the rotary joint!
Use flexible metal hoses for the connection between the supply pipe system and the rotary joint hous-
ing. This compensates for heat expansion and vibrations.
Never apply torsional, tensile or pressure forces to metal hoses. Observe the minimum bending radii
quoted by the hose manufacturers. Never use axial compensators.
Use flat packings made of pure graphite to securely seal flange connections.
Only operate rotary joints sizes DN 65 … 100 with a sufficiently dimensioned torque support. The sup-
port element must allow for axial and radial movements of the housing. For sizes DN 06 … 50, due to
low friction torque support by the hoses is sufficient.
For DN 65 and greater install an additional safety unit:
Install a torque monitoring system or a bearing monitoring system with vibration pickup (e.g. FAG or
SKF) with connection to the emergency shutdown system in order to avoid bearing damages and con-
sequential damages.
If the monitoring system is activated, the rotation of the roller should be stopped immediately and the
supply of the medium should be interrupted upstream of the metal hoses.
Center the inner pipe and the roller as well as the rotary joint. Run-out and axial tension will lead to mal-
functions of the rotary joint.
For smooth operation of rotary joint ensure concentricity and minimum run-out tolerance at roller or in-
termediate flange.
In the case of a rotary joint with rotating inner pipe it is recommended to use a stainless steel inner pipe
or at least a hard chromium-plated bearing seat.
Operation at water temperatures exceeding 70°C (158°F):
In order to ensure maximum reliability and service life of the seals in the rotary joint, the hot water used
in the rotary joint must be processed, treated and conditioned according to the DdTÜV Guidelines Tech-
nical Chemistry 1466 (VdTÜV - Merkblatt Technische Chemie 1466). The circulated water must have a
low salt concentration and a maximum conductivity of < 100 S/cm (100µmho/cm)!
If the salt concentration is high, this may result in deposits in the seal gap and premature failure of the
seal!
4 Transportation and storage
The rotary joints may only be stored in the original package.
Make sure the storage conditions specified in the "Specifications and Spare Parts" are met.
If the rotary joint itself or the facility in which the rotary joint is installed is to be preserved, make sure the
preservation agent and the seals of the rotary joint are compatible.

Operating Instructions Maier Rotary Joints
Series DP B-DP_en -Version 4 – 14.02.2011
Keep these instructions for future reference! 5
5 Mounting
5.1 Mounting the rotary joint to the roller
Mount rotary joint 1 to roller W:
as per drawing A with thread at rotor
as per drawing B with K flange 2 and inner ring 3
as per drawing C with fixed flange 4.
Seal with a sealing cone (rotor R/L), O ring 6, flat packing 7
or another suitable sealing element.
Fasten the rotary joint with screw 8 or stud bolt 9 and nut 10.
Clean sealing surfaces DF.
Place the sealing element into roller W (drawing B).
Recommended material for flat packing:
pure graphite with metal insert.
Duo version rotary joint:
version P 2: screw inner pipe J into angle piece
version PR 2: insert inner pipe J into the angle piece, center
the pipe, no tension allowed.
version PO 2: screw inner pipe J with O ring and anti-rotation
unit into angle piece (inner pipe available for type PO2).
Mount K flange 2 with screws over rotor 80 and place inner
ring 3 into rotor groove. Mount stud bolts 9 (drawing B).
Lift the rotary joint and insert it into the centering unit of the
roller.
Versions with inner pipe: the inner pipe must be centered
with reference to the rotary joint and the roller. If you en-
counter resistance, check for correct position. Run-out and
axial tension cause malfunctions of the rotary joint.
Mount screws 8, 11 and nuts 10. Maximum admissible tor-
que as per "Specifications and Spare parts".
Attention:
When sealing with flat packing, do not fully tighten the
screws until you have aligned the rotary joint as per sec-
tion 5.2!
Assure the minimum distance MA is at least 1mm - oth-
erwise leakage will occur at the sealing element and the
rotary joint and the inner pipe will be damaged:
drawing B : MA ≥1 mm (0.04”)
drawing C : MA1 = 0 mm (0.00”)
MA2 ≥1 mm (0.04”)
Note!
For smooth operation of rotary
joint ensure concentricity and minimum
run-out tolerance of roller
Fig 7. Mounting the rotary joint to the
roller

Operating Instructions Maier Rotary Joints
Series DP B-DP_en -Version 4 – 14.02.2011
Keep these instructions for future reference! 6
5.2 Aligning the rotary joint, sealing with flat packing
Place dial gauge M from the idle machine frame MG
onto the rotary joint.
Rotate roller W until the dial gauge is at the bottom
dead center UT. Mark the pointer position.
Rotate roller until you reach the upper dead center
OT.
Tighten the bottom screws Su until the dial gauge is
in the center position.
Repeat this alignment process until you reach the
concentricity tolerance specified in the table.
Tighten the screws with the admissible torque as per
"Specifications and Spare Parts"!
Fig 8. Aligning the rotary joint
Admissible concentricity tolerance
n (min-1 / rpm)
DN [mm] DN [inch] 100 400 > 400
03-50 1/8- 2 0,25mm (±0.01″)
65 - 100 2½ - 4 ± 0,1mm (±0.004″)
5.3 Connecting the rotary joint
Attention!
The rotary joints must never run dry since this may damage them. Exception: test
run for a maximum of 30 minutes a very low speeds.
Mount torque monitor or vibration pickup.
Connect the housing.
Route the hoses as shown in fig. 4.
Do not route the hoses as shown in fig. 5.
.
Note!
Observe the information in section 3!
Fig 9. Connecting the rotary joint

Operating Instructions Maier Rotary Joints
Series DP B-DP_en -Version 4 – 14.02.2011
Keep these instructions for future reference! 7
6 Operation
Attention!
Danger of damage to the rotary joint if is not operated as per instructions.
Never operate the rotary joint beyond the application data limits specified in
"Specifications and Spare Parts"!
Observe the limitations specified in section 0 on page 2!
6.1 Observe and check during operation
Check the following during operation:
Check for centric arrangement of the rotor with reference to the roller cog. The radial deflection at the
rear area of the housing must not exceed the values in chapter 5.2 (Admissible concentricity tolerance).
Place a dial gauge from the idle machine frame onto the rotary joint housing to check.
Check the quality of the medium in the system and record the values.
Check for visible leaks at the relief connection of the rotary joint. The operating behavior of the rotating
mechanical seal installed does not change suddenly. If the seal is beginning to fail, this is indicated by
slowly increasing leakage. Regular checks allow you to acquire values concerning the operating behav-
ior of the rotary joint installed in the system.
6.2 Troubleshooting
Problem Reason Repair
Leakage at the hous-
ing via the relief holes
Rotating mechanical seal is
damaged or worn.
Install a new rotating mechanical seal. Check the quality of
the medium and the bearings.

Operating Instructions Maier Rotary Joints
Series DP B-DP_en -Version 4 – 14.02.2011
Keep these instructions for future reference! 8
7 Maintenance
7.1 Safety during maintenance
Only staff that has read and fully understood these operating instructions and that is fully aware of the dan-
gers resulting from the rotary joint as well as the appropriate safety precautions may work with Maier rotary
joints. Such staff must have at least the knowledge of a trained locksmith or industrial mechanic who has
experience with pressurized components.
Perform work on the rotary joint only when the machine/system is idle.
Allow the rotary joint to cool down before you take up work or wear safety equipment to protect against the
heat.
Always wear safety glasses when performing work on the rotary joint to protect against escaping medium.
Use only genuine Maier or Maier-approved spare parts (standard norm parts). If you use other parts, this
may have adverse effects on the safety of the rotary joint.
Maier offers on site specialist service. We can also train your service staff - just get in touch with us!
If you have to remove protective equipment to perform the work, refit such equipment when you are done
and check it for proper operation.
Make sure to properly tighten all screws (see sheet "Specifications and Dimensions").
Always observe the safety information in chapter 1 on page 2.
7.2 Maintenance plan
Due to lifetime lubrication, the rotary joints are maintenance-free up to operating temperatures of up to
max. 80°C (176°F). The bearings must be lubricated if the rotary joints are operated at greater tempera-
tures. Please refer to "Specifications and Spare Parts" for information on lubrication intervals and volumes.
Interval Activity Explanation
According to section
"Specifications and
Spare Parts“
Lubricate DP rotary joints depending
on operating temperature.
Lubrication volume depends on the nominal di-
ameter of the rotary joint (see section "Specifi-
cations and Spare Parts“).
Every 12 months Check all bearings and seals and
replace them
By Maier customer service

Specifications and Spare Parts
Series DP S-DP_en -Version 7 – 16.02.2011
Keep these instructions for future reference! S1
Contents
Table 1: Application data ................................................................................................................................................................1
Table 2: Transportation and storage ...............................................................................................................................................1
Table 3: Bearing lubrication ............................................................................................................................................................2
Table 4: Tightening Torques for Fastening Screws.........................................................................................................................2
Approved media for the pressure pipe ............................................................................................................................................3
Specifications - standard media......................................................................................................................................................3
DP DN 10 – 50 (3/8 ″- 2″)...............................................................................................................................................................5
P N 10 … 50 (3/8’’ … 2’’) .................................................................................................................................................................6
DP … -800 DN 10 … 50 (3/8’’ … 2’’)..............................................................................................................................................7
P …- 800 DN 10 – 50 (3/8’’ … 2’’)....................................................................................................................................................8
At DN 15 and 20: Elbow with additional adapter! ............................................................................................................................8
Inner pipe for Elbow PO 2 …- 800 ..................................................................................................................................................8
DP Spare parts DN 10 – 50 (3/8’’ … 2’’) ..........................................................................................................................................9
DP DN 06 and Spare Parts...........................................................................................................................................................10
DP1 DN 65 – 100 (2½″- 4″) ........................................................................................................................................................11
DP2 DN 65 – 100 (2½″- 4″) ........................................................................................................................................................12
DPR2 DN 65 – 100 (2½″- 4″)......................................................................................................................................................13
Spare Parts for types DP1, 1, R2, - DN 65 – 100 (2½″-4″) .........................................................................................................14
DPN1 D 10 – 50 (3/8″- 2″)............................................................................................................................................................15
DPN2, DPNR2 DN 10 – 50 (3/8″- 2″) ...........................................................................................................................................16
Spare Parts for types DPN1, 2, R2, - DN 10 – 50 (3/8″- 2″).........................................................................................................17
Journal Flanges for K Rotor Connection .......................................................................................................................................18
Table 1: Application data
Series DP DP DP-800 DP DPN
Type 1, 2, R2 1B, 1C, 2,
R2
Nominal diameter DN
Nominal diameter DN
[mm]
[inch]
…06
… 4
1
10 … 50
8
3… 2
10 … 50
8
3… 2
65 … 100
22
1… 4
10 … 50
8
3… 2
Medium
Compres-
sed air,
water
Hydraulic
Oil Water Thermal Oil Water Water
Temperature max. °C
max. °F
… 120
… 248
… 80
… 176
-10 … 160
14 … 320
… 160
… 320
-10 … 140
14 … 284
-10 … 90
14 … 194
Pressure PN, min.…max. bar
min… max. psi
… 10
… 145
… 80
1160
-0,2 … 10
-2.9 …145
… 10
… 145
-0,2 … 10
-2.9 ...145
-0,2 … 10
-2.9 … 10
Speed max. min-1
max. rpm 55000
DN [mm]
55000
DN [mm]
55000
DN [mm]
55000
DN [mm]
55000
DN [mm]
Speed limite
for formula values
max. min-1
max. rpm 3000 400 2500 2500 850 2500
Avoid operating the unit under conditions involving several maximum values attained at the same time! Inquire for
greater values and other media.
Table 2: Transportation and storage
Storage temperature 15 °C to 30 °C
59 °F to 86 °F
Humidity 65 %
Preservation none; check compatibility with seal materials, if neces-
sary