Voith IPH Series User manual

Internal Gear Pumps
IPH – IPC – IPV(S) – IPVP(X) – IPVA –
IPN(E) – IPM(E)
Operating instructions 2016-04-01
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Voith Turbo H + L Hydraulic GmbH & Co. KG 25000057510-TED-ENX-04
Contact
If you have any questions about our
products, please contact us with the serial
number and the model number at:
Voith Turbo H + L Hydraulic GmbH & Co. KG
Service Department
Schuckertstraße 15
71277 Rutesheim
Germany
Additional contact information:
Telefon [phone]
Telefax [phone]
[email protected]
www.voith.com/hydraulic-systems
Voith Turbo H + L Hydraulic
GmbH & Co. KG
Schuckertstr. 15
D-71277 Rutesheim
25000057510-TED-DEX-04
April 2016
© 2016, Voith Turbo H + L Hydraulic
GmbH & Co. KG
The original language is german. This docu-
ment is a translated version.
This documentation, including all its parts,
is copyright protected. Any utilization or
modication beyond the restrictive limits of
copyright law without approval by
Voith Turbo H + L Hydraulic is not permitted
and liable to prosecution.
This applies particularly to reproductions,
translations, microlming, and storage and
processing in electronic systems.
Publisher
Document number
Issue date
Copyright
Language
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Voith Turbo H + L Hydraulic GmbH & Co. KG 25000057510-TED-ENX-04
Table of contents
1 Quick start guide 7
1.1 Description, Application 7
1.2 Start up procedure Voith internal gear pumps 7
2 About this guide 10
2.1 Product observation 10
2.2 Additional documentation 11
2.3 Signs and symbols used 11
2.3.1 General signs and symbols 11
2.3.2 Safety signs and symbols 12
3 General safety regulations 13
3.1 Designated use 13
3.1.1 Areas of applications 13
3.1.2 Foreseeable misuse or improper handling 14
3.1.3 Other dangers 14
3.2 Personnel–Qualicationandobligations 15
3.3 Personnel – Protective equipment 16
3.4 Spare parts 16
3.5 Generalsafetyinformation 17
3.6 Safety information and warning notices 19
4 EU directives, regulations, and standards 19
4.1 EU directives 19
4.2 Standards (ISO, EN, DIN) 19
5 Voithinternalgearpumps 20
5.1 Designandfunctionality 20
5.1.1 Sickle principle 20
5.1.2 Superlip principle 21
6 Pressureuids 22
Internal gear pumps
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7 Packaging, transport 24
7.1 Packaging 24
7.2 Delivery 24
7.3 Transport 25
8 Storage, preservation 28
8.1 Storage 28
8.2 Preservation 28
9 Assembly 29
9.1 Assembly of pump and motor 29
9.2 Pump installation 30
9.2.1 Installation position 30
9.2.2 Initial preparations 30
9.2.3 Assembly steps 31
9.2.4 Pipelines and ange 32
10 Operational testing and commissioning 33
10.1 Checking the direction of rotation 33
10.2 Speed 33
10.2.1 Performance pump 33
10.2.2 Variable-speed pump 33
10.3 Filling / bleeding the pump 34
10.4 Bleeding the system 34
10.5 Commissioningthepump 35
11 Voith internal gear pumps in operation 37
11.1 Operating data 37
11.1.1 Factors that inuence the loss of pressure
in the suction piping during operation 37
11.1.2 Suction pressure 37
11.1.3 Pressure side 38
11.1.4 Suction pressure 38
11.1.5 Reverse mode on variable-speed pumps 38
12 Shutting down 38
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13 Disassembly 39
14 Disposal / Recycling 40
15 Maintenance 41
16 Faults and solutions 42
17 Pump combination planning 44
17.1 Planning information 44
17.1.1 Design and principle of operation of the Voith internal gear pumps 44
17.1.2 Key data of the Voith internal gear pumps 44
17.1.3 Drive motor 44
17.1.4 Coupling 45
17.1.5 Noise emissions of the Voith internal gear pumps 45
17.2 Pumpcombinations 45
17.3 Torques 47
17.3.1 Calculating the torque of a hydraulic pump 47
17.3.2 Calculating the overall torque of a multi-stage pump 47
17.3.3 Calculating the torque on the secondary shafts (coupling sleeves) 48
17.4 Permitted input torques for Voith internal gear pumps 49
17.5 Supportforpumpcombinations 49
17.6 Pipelines 51
17.6.1 Factors that inuence the loss of pressure in the suction piping 52
17.7 Oilreservoir 52
17.8 Filtration 53
18 Declarationontheinstallationofanincompletemachine 54
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Voith Turbo H + L Hydraulic GmbH & Co. KG 25000057510-TED-ENX-04
List of illustrations
Fig. 5.1.1: Components of the internal gear pump with sickle principle 20
Fig. 5.1.2: Components of the internal gear pump with superlip principle 21
Fig. 7.1: Steel ring screw with plastic shim 25
Fig. 7.2: Screwing in the ring screws 25
Fig. 7.3: Hanging a pump combination on to ring screws 27
Fig. 9.1: Examples of designs and installation locations 30
Fig. 10.1: Wiring diagram of the pressure limiting valve 35
Fig. 10.6: Temperature sensor 36
Fig. 17.1: Examples of pump combinations 45
Fig. 17.3: Calculating the torque for secondary shafts 48
Fig. 17.5: Permitted torque on the mounting ange,
horizontal installation position 50
Fig. 17.6: Conguration of the pump suction piping 51
List of tables
Tab. 4.2: Standards 19
Tab. 6.1: Requirements 22
Tab. 6.2: Limitations 23
Tab. 7.3: Drive shaft internal thread 27
Tab. 16.1: Operating faults and solutions table 42
Tab. 17.4: Permitted input torques 49
Tab. 17.5: Permitted inertia on the mounting ange,
horizontal installation position 50
Internal gear pumps
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Voith Turbo H + L Hydraulic GmbH & Co. KG 25000057510-TED-ENX-04
1 Quick start guide
1.1 Description, use
All Voith internal gear pumps are delivered with a quick start guide. The guide
describes how to commission the internal gear pump correctly on initial start-up.
The quick start guide is no replacement for the main comprehensive operating
instructions, and should instead be used solely as a supplement.
The quick start guide comprises two DIN A4 pages only, and is written in German
and English. Other languages are available on request.
1.2 Quick start guide Voith Internal gear pumps
Before installing and commissioning the internal gear pumps, you must have rst
read and understood the operating instructions.
• Assembly and commissioning must Important notes: only be carried out by
trained personnel who have been briefed on the system.
• The pumps must only be operated with the permitted data.
• The hydraulic system must be depressurized before any work is carried out on
the pumps.
• Safety guards must be attached, and the existing safety guards must not be
removed.
• Always ensure all fastening screws are correctly attached, and if necessary check
the correct tightening torque.
• The general safety and accident prevention guidelines must be observed.
• The pumps delivered by us are assembled in accordance with the current
drawings and bills of material. No alterations of any kind are allowed, otherwise
this will void the warranty.
• Repairs may only be made by the manufacturer or authorized dealers and outlets.
No guarantee will be accepted for repairs made by the customer.
Important notes:
General:
Internal gear pumps
Quick start guide
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Preparation
• Assemble the coupling parts without
unnecessary force (i.e. without
knocks or pressing). Use the thread
tapped hole in the shaft end.
• Check that the direction of rotation of
the drive and the pump match.
• Note the arrow indicating the direc-
tion of rotation on the pump housing
or the rating plate.
• Attach the pump and ensure there
are no axial or transverse forces
acting on the drive (coupling direc-
tion).
• Remove the core plugs on the pump.
• Prell the pump with operating uid
via the suction port.
• Relieve the delivery pipe, set the
directional control valve and/or pres-
sure limiting valve to unpressurized
circulation (note the charging pressu-
re through any existing check valves).
• Pipelines must be leak-proof.
• Delivery pipes must not be lled with
operating uid.
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Quick start guide
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Voith Turbo H + L Hydraulic GmbH & Co. KG 25000057510-TED-ENX-04
Commissioning
• Starting up the electric motor in tip operation.
• Check the direction of rotation.
• Bleed the delivery pipe, e.g. via the measuring connection, until operating uid is
discharged free of bubbles. The required operating pressure may now be set, but
not before.
• With a preloading valve of >1 bar, the system must be bled between the pump
and the preloading valve.
• If the suction port is situated below and the oil level is below the pump, take
special care during the bleed process!
• The system is only bled when there are no jarring noises and there is no foam
build-up in the tank.
• The pump can now be loaded with the operating pressure.
• With a positive oil inlet, the pump must be bled via the bleeder screw in the end
cover. Opening the bleeder screw allows the air to be bled out of the pump (while
the pump is shut down).
• The pump must not be operated with an opened bleeder screw. Operating the
pump while the bleeder screws are open will damage the pump.
NOTE
If these points are ignored, the pump could be damaged.
Internal gear pumps
Quick start guide
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Voith Turbo H + L Hydraulic GmbH & Co. KG 25000057510-TED-ENX-04
2 About this guide
These operating instructions describe how to install and operate the internal gear
pumps in a normal atmosphere, or with operating uid.
If used in an area at risk of explosions, please follow the necessary standards,
e.g. ATEX.
Before using internal gear pumps, ensure you have carefully read and understood
the operating instructions. By using the operating instructions, you will become
familiar with basic operations involving the internal gear pump, from installation
through to recycling.
These instructions contain important notes about operating the pump safely and
correctly. Following this information will help:
• avoid danger
• reduce repair costs and downtime
• increase the reliability and service life of the pump
In addition to the operating instructions, you must observe the
• local laws, ordinances, guidelines, and standards,
• local regulations for accident prevention and environmental protection,
• operating instructions of the system or machine in which the pump is used
A copy of the operating instructions must be available to operating personnel at all
times.
The operating instructions for internal gear pumps are a component of the manual
for the overall system.
2.1 Product observation
Voith is legally obligated to observe our products, even after their delivery.
Please inform us about anything that may be of interest to us.
Specically, this includes:
• altered operating data
• experiences with the pump
• any recurring malfunctions
• damage to the pump
• difculties with the operating instructions
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Voith Turbo H + L Hydraulic GmbH & Co. KG 25000057510-TED-ENX-04
Internal gear pumps
About this guide
2.2 Other documentation
In addition to these instructions, other documentation on the internal gear pumps
is also available. These documents are an integral addition to the operating instruc-
tions under the terms of EC Directive 2006/42/EG.
You can request these documents from Voith Turbo H + L Hydraulic:
• Planning, installing, and commissioning Voith internal gear pumps
• Internal gear pump catalogs
• General conditions of delivery
• ATEX
• Risk assessment report in accordance with EN 13463 (positive list) relating to
pump type IP** by VOITH TURBO for use in explosive atmospheres, e I/ II
M2/2GD ck IIB (T4) Extract from operating instructions relevant to explosion
protection in respect of type IP*** explosion-protected pumps
• Declaration of conformity: ExGuide 04 ATEX 021
2.3 Symbols used
The symbols in the operating instructions should help you use the operating instruc-
tions and device both quickly and safely.
2.3.1 General symbols
Advanced Organizer
The Advanced Organizer provides concise information about the contents in the
subsequent chapter.
Note
Application notes and other useful information.
Handling steps
The dened sequence of the handling steps makes it easier to use the pump
correctly and safely.
Result
The result of a sequence of handling steps are described here.
List
Indicates individual list elements.


1.
2.
3.
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2.3.2 Safety symbols
The safety symbol graphically represents a source of danger. The safety symbols in the
working range of the machine/system and the entire technical documentation corres-
ponds to the coordinated standard EN 61310 section 2: Safety of machines – display-
ing, identifying, and operating, or EC Directive 92/58/EEC (minimum requirements for
health and/or safety signs at work).
Warning symbols
Warning about a general danger
Warning of hazardous electrical
voltage
Warning about hot surface
Warning about the risk of crushing
Warning about hand injuries
Warning about danger due to
rotating parts
Warning about danger due to
suspended loads
This warning symbol is placed before
activities which can lead to multiple
sources of danger.
This warning symbol is placed before
activities where there is a risk of electric
shock, with potentially fatal consequen-
ces.
This warning symbol is placed before
activities where there is danger of hot
surfaces.
This warning symbol is placed before
activities where there is a risk of being
crushed, with potentially fatal conse-
quences.
This warning symbol is placed before
activities where there is a risk of hand
injury.
This warning symbol is placed before
activities where there is danger of rota-
ting machine parts.
This warning symbol is placed before
activities where there is danger of swin-
ging loads.
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Voith Turbo H + L Hydraulic GmbH & Co. KG 25000057510-TED-ENX-04
3 General safety regulations
This section contains basic safety regulations for operating internal gear pumps.
Always follow the safety regulations!
3.1 Designated use
The internal gear pumps are compliant with the latest developments in science and
technology and the applicable safety regulations at the time of initial manufacture,
in the context of designated use.
Neither foreseeable misuse nor additional dangers can be structurally avoided
without restricting the designated functionality.
Danger can be avoided by following special warning notices in the technical docu-
mentation.
3.1.1 Applications
The internal gear pumps are designed and built solely in order to generate pressure
uid volume ow with a specied pressure.
Internal gear pumps are designed for use
• as a drive in hydraulic systems as control elements,
• and in tool machines as cooling lubricant pumps IPME.
Pressureuids
In addition to hydraulic oils with a mineral oil base, environmentally-friendly uids
and other special uids also act as pressure uids. For more information, see
chapter 6 “Pressure uids”.
Operate the internal gear pumps in accordance with the technical documentation.
The manufacturer shall not be liable for any damage resulting from improper use.
The operator assumes all risk.
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3.1.2 Foreseeable misuse or improper handling
In the case of foreseeable misuse or improper handling of the internal gear pump,
the declaration of incorporation from the manufacturer shall no longer be valid, and
the operating license shall also expire automatically.
Foreseeable misuse or improper handling are:
• Use of non-approved pressure uids (see chapter 6 “Pressure uids”).
• Exceeding the permitted operating data, e.g. input torques.
• Exceeding or undershooting the permitted drive speed.
• Failing to observe the regulations of the manufacturer regarding operation,
maintenance, and servicing as listed in the operating instructions.
• Carrying out work on the pumps by a specialist who is not approved or specially
trained by the manufacturer.
• Arbitrary alterations and modications that affect the safety of pumps and the
system.
• Operating the pumps in non-approved areas and overload conditions.
• Neglecting the specied maintenance work, and failing to observe the mainte-
nance and inspection intervals.
• Failing to make measurements and perform tests for early detection of damage.
• Incorrectly performed maintenance or repair work.
3.1.3 Other dangers
Before beginning design and planning, the remaining dangers associated with
internal gear pumps were analyzed and assessed.
Remaining dangers that are unavoidable due to design during the overall life cycle
of the pumps are:
• Danger to life
• Risk of injury
• Health hazard
• Environmental risk
• Physical damage to the pump
• Physical damage to other material assets
Any existing remaining dangers are avoided by the practical implementation and
observation of:
• special warning notices in the operating instructions
• the general safety information in the operating instructions
• the operating instructions of the operator
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General safety regulations
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Voith Turbo H + L Hydraulic GmbH & Co. KG 25000057510-TED-ENX-04
Danger to life of persons can arise on the pumps due to:
• misuse
• improper handling
• transport
• defective or damaged mechanical components
Risk of injury to persons can arise on the pumps due to:
• improper handling
• transport
• defective or damaged mechanical components
• falling or tipping pumps
Danger to the health of persons can arise on the pumps due to:
• uids, cleaning and preservation media
Risk to the environment can arise on the pumps due to
• improper handling
• leaks
• improper disposal of the pressure uids, cleaning and preservation media
Physical damage to the internal gear pumps can arise due to:
• improper handling
• failing to observe the operating and maintenance requirements
• improper operating materials
Physical damage to other material assets in the operating range of the pumps can
arise due to:
• improper handling
3.2 Personnel–Qualicationandobligations
All work carried out on internal gear pumps must be carried out by specially
authorized personnel.
Authorized personnel must
• be 18 years of age
• have read and understood the chapter entitled “General safety regulations”
• practically apply and implement the contents of the chapter entitled “General
safety regulations”
• possess the physical and mental capabilities for carrying out their responsibilities,
tasks, and activities on the pumps
Internal gear pumps
General safety regulations
Danger to life
Risk of injury
Health hazard
Environmental risk
Physical damage to
the internal gear
pumps
Physical damage to
other material as-
sets
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Voith Turbo H + L Hydraulic GmbH & Co. KG 25000057510-TED-ENX-04
Authorized personnel must
• be trained and instructed in accordance with their responsibilities, tasks, and
activities on the pumps,
• be familiar with and be able to use the components of the hydraulic system and
their functionality,
• and be able to practically implement the technical documentation regarding their
responsibilities, tasks, and activities on the pumps.
Authorized personnel are
• responsible for preventing unauthorized operation of the pump,
• obligated to comply with the applicable accident prevention regulations,
• obligated to wear personal protective equipment,
• obligated to keep unauthorized personnel out of the danger zone associated with
the pump.
The authorized personnel are responsible for
• conrming the safety and notice symbols on the pumps are in good legible
condition,
• carrying out repairs only following consultation with the manufacturer,
• making sure that the pumps are protected from unauthorized use,
• ensuring the pumps are only operated when they are fully functional and safe
for operation,
• ensuring they have the necessary training for internal gear pumps and hydraulic
systems.
3.3 Personal protective equipment
The following personal protective equipment must be worn/used for all activities
involving the internal gear pumps described in these operating instructions:
• Protective gloves
• Hand protection cream
• Protective shoes
• Safety helmet (as needed)
• Hearing protection (as needed)
3.4 Spare parts
Spare parts must meet the technical specications of Voith Turbo. This is guaran-
teed with genuine spare parts as they are subjected to constant quality control in
accordance with DIN ISO 9001 or EN 29001. Third-party spare parts may in some
cases alter the specied structural characteristics of the machine and lead to
signicant deciencies beyond the control of Voith Turbo H + L Hydraulic.
Internal gear pumps
General safety regulations
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Voith Turbo H + L Hydraulic GmbH & Co. KG 25000057510-TED-ENX-04
3.5 Generalsafetyinformation
Protect the pumps from dirt and contaminants during operation.
Lift and transport the internal gear pumps with sufciently dimensioned transport
aids.
Place the internal gear pumps on a sufcientlysturdy oor on a wooden base. Pay
attention to the center of gravity (axis of travel) when assembling combination
pumps.
Check the functionality and operating safety of the pump, the overall system, and in
particular, the overpressure control valve and safety valve before each start-up.
Before restarting a shutdown system again, remedy the cause of the shut down
(i.e. maintenance work, emergency stop).
Only start up a fully functioning and operationally safe pump/system.
Only use the safety equipment settings as dened in the machine manufacturer’s
operating instructions.
Do not make any alterations to tested, approved, and sealed safety and overpres-
sure valves.
Only run a fully functional and securely operating pump/system. Shut down the pump
immediately when abnormal operating conditions or malfunctions occur.
Report abnormal operating conditions or malfunctions immediately.
Risk of burns: during normal operation, surface temperatures of ≥ 60°C are possible.
In the event of unpermitted overloads, even higher temperatures can occur.
Noise is produced when the pump is operated. If required, protective measures
may be necessary at the machine or via PPE.
Fluids are generally ammable. Beware of the risk of re and explosion!
Pressure uids are generally poisonous, irritating, and/or will burn. Avoid contact
with the skin and eyes.
Discharged pressure uids (even small leaks) may leave an oily coating. Danger
of slipping or falling!
Protection
Transport
Assembly
Commissioning
Safety equipment
Operation
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General safety regulations
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Voith Turbo H + L Hydraulic GmbH & Co. KG 25000057510-TED-ENX-04
Do not clean the pumps while in operation.
Follow the cleaning intervals.
Do not perform any maintenance or service work while the pump is in operation. The
maintenance intervals in these operating instructions must be maintained.
Only the maintenance work described in these instructions may be carried out by the
operator service personnel.
All other maintenance work (particularly pump overhauls) may only be performed
by the manufacturer service personnel or by personnel trained by the manufacturer.
Do not perform any repair work while the pump is in operation.
Carry out repairs only following consultation with the manufacturer.
Use suitable tools for the maintenance work. Expert maintenance or repairs can only
be guaranteed by the manufacturer or authorized companies.
Unusable internal gear pumps should be sent for recycling in accordance with the
local environmental protection guidelines.
A copy of these operating instructions must be available to authorized personnel at
all times.
These instructions must always be kept with the operating instructions to be created
by the operator.
Recycle the packaging material in accordance with regulations for environmental
protection applicable at the site of use.
Recycle used or residual operating materials in accordance with the regulations ap-
plicable at the site of use.
Cleaning
Maintenance
Repairs
Shutdown /
disassembly
Documentation
Environmental
protection
Internal gear pumps
Allgemeine Sicherheitsbestimmungen
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Voith Turbo H + L Hydraulic GmbH & Co. KG 25000057510-TED-ENX-04
3.6 Safety information and warning notices
Special safety information may be necessary for certain work. This safety informa-
tion can be found in the operating instructions for the respective activity. They are
clearly highlighted with a warning symbol. Different signal words are used depending
on the degree of danger.
Signal word Used for Potential consequences if safety
information is not followed:
DANGER Personal injury (immediate
threat of danger)
Serious injury!
WARNING Personal injury (a potentially
dangerous situation)
Serious injury!
CAUTION Personal injury Slight or minor injury
Physical damage Material damage to the system or the
surroundings
4 EU directives,
regulations, and standards
In this section, you will nd a list of the applicable directives, regulations, and
standards.
4.1 EU directives
The following EU directives have been followed, and should be taken into account
when using the product: 2006/42/EC of May 17, 2006 on machinery
4.2 Standards (ISO, EN, DIN)
The following standards have been followed, and should be taken into account when
using the product:
Number Designation
DIN ISO 12100-1
Safety of machinery – Basic concepts, general principles for
design – Part 1: Basic terminology, methodology.
DIN ISO 12100-2
Safety of machinery – Basic concepts, general principles for
design – Part 2: Technical guidelines and specications.
ISO 4413
Hydraulic uid power – General rules and safety requirements
for systems and their components
DIN ISO 62079 Preparation of instructions, structuring and content
Tab. 4.2: Standards
Internal gear pumps
EU directives, regulations, and standards
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5 Voith internal gear pumps
This section contains a description of the components and functionality of internal
gear pumps.
5.1 Designandfunctionality
5.1.1Sickleprinciple
Fig. 5.1.1: Components of internal gear pump with sickle principle
When the gears rotate in the pump the pressure uid (as a rule hydraulic oil) is drawn
into the cavity between the pinion and internal gear. The two smoothly running gears
help to ensure excellent intake behavior.
In the radial direction, the gear chambers are sealed by gear meshing and/or the ller
piece. In the axial direction, the axial plates seal the pressure chamber with the minimal
possible gap. This design minimizes volume losses and increases efciency. When the
gears rotate, the pinion teeth enter the gaps between the internal gear teeth and
displace the pressure uid.
Individual pumps suck via the radial suction port on the pump housing. With two-ow
and multi-ow pumps, suction is generally possible via the suction port on the interim
housing. For low-noise operation of the pumps, the low pump ow and pressure pulsa-
tion usually help.
1 Pinion shaft
2 Internal gear
3 Filler pin
4a Filler segment carrier
4b Filler sealing segment
5 Axial disc
6 Axial pressure area
7 Plain bearings
8 Housing
9 Hydrostatic bearing
10 End cover
1 7 6 5 9 2 5 6 7 10 8 2 1 9 4a 4b 3
Internal gear pumps
Design and functionality
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