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Progressing cavity pump
Operating and maintenance instructions
with instructions for assembly and disassembly
Retain the original operating instructions for future use!
This manual is a translation of the VM 760.0002 - D 150 500, Issue 2011.11.
Refer to the order-specific section of the documentation for operational data, dimensions, and other
additional information.
Order No.:
Machine No.:
Insert image(s)
Edition
BA-2011.11
Print No.
150 500
VM No.
760.0002 GB
Subject to technical changes!
Important note:
These operating instructions are supplemented with order-specific information.
Series AE1F, AE1L
AE.E, AE.N, AE.H,
AE.V, AED1E, AED2N
ID, ZD construction types
Pump ID No.:
Pump model:
ALLWEILER AG – Bottrop plant
P.O. Box 200123 · 46223 Bottrop
Kirchhellener Ring 77-79 · 46244 Bottrop
Germany
Telephone: +49 (0) 2045-966-60
Fax:
+49 (0) 2045 966-679
E-mail:
service@allweiler.de
Internet:
www.allweiler.com
,
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Summary of Contents for Allweiler AE1F Series
- Page 1 Order No.: Pump ID No.: Machine No.: Pump model: Insert image(s) Edition BA-2011.11 ALLWEILER AG – Bottrop plant Print No. 150 500 P.O. Box 200123 · 46223 Bottrop VM No. 760.0002 GB Kirchhellener Ring 77-79 · 46244 Bottrop Germany...
- Page 2 These operating and maintenance instructions contain notices from the pump manufacturer. It may be necessary to amend these instructions with instructions from the company that operates the pump. Specific notices about operating and maintaining the overall system in which the pump is integrated are not provided here. These must be provided by the persons who are responsible for planning and constructing the system (system manufacturer).
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Page 3: Table Of Contents
Table of Contents Table of Contents 1 About these instructions ......1 Performance data ......7 Design ......... 7 Who should read these 4.4.1 Structural design ......7 instructions ........1 4.4.2 Bearing and lubrication ....7 Related documents ...... 1 4.4.3 Shaft seal ........ - Page 4 Table of Contents Safety and inspection 10.1.1 Disassembling the progressing equipment ........17 cavity pump ....... 26 6.7.1 Pressure and vacuum gauges ... 17 10.1.2 Removing the stator ....26 6.7.2 Safety device in the pressure 10.1.3 Removing the rotor and rotor- line ..........
- Page 5 Table of Contents 11.4 Section drawings for series AE1+1H, AE2+2H, AE2+2V, AE4+4V; ID construction type ..45 11.5 Sectional drawings for series AE2H, AE4H; ID construction type ..........46 11.6 Sectional drawing for series AE1N, AE2N; ZD construction type ..........47 11.7 Sectional drawing for series AE1+1H, AE2+2H;...
- Page 6 Table of Figures Table of Figures Fig. 1 Nameplate (example) ......7 Fig. 33 Sectional drawings for series AE2H, AE4H; ID construction type ..46 Fig. 2 ATEX nameplate ........7 Fig. 34 Sectional drawing of series AE1N, Fig. 3 Model code ..........7 AE2N;...
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Page 7: About These Instructions
About these instructions Who should read these instructions the machine. These residual hazards are About these instructions related to: These instructions: • people • are part of the pump • the machine • are valid for the specified series and •... -
Page 8: Technical Terms
About these instructions Technical terms 1.7 Inspection 1.4 Technical terms All pumps are subjected to leak and Pump: "Pump" refers to the pump without performance tests before leaving our factory. coupling, drive, or any other components. Only flawlessly operating pumps that meet our Pump unit: "Pump unit"... -
Page 9: Safety
In addition to the documentation, comply Any other or additional usage is improper with all legal and other safety and usage. ALLWEILER will not be liable for any accident-prevention regulations as well as resulting damages. applicable standards and directives in the Proper use also refers to observation of all country of operation. -
Page 10: Operator's Responsibilities
Safety Safety precautions Lack of clarity regarding responsibilities 2.4.2 Operator’s responsibilities represents a safety risk. Work in a safe manner All persons who perform activities on the machine must read the operating instructions ► Operate the pump in accordance with and confirm with their signature that they have these instructions and in a technically understood the operating instructions. -
Page 11: Unauthorized Conversion And Production Of Spare Parts
Safety Unauthorized conversion and production of spare parts 2.9 Protective clothing Pumps or systems that move hazardous liquids must be decontaminated. The points listed under the section "Initial startup" ( page 18) must be observed before Protective gloves bringing the machine back into operation. Wear protective gloves at all times. -
Page 12: Danger Points
Danger points Hazards when working with the system The machine’s electrical equipment must be Danger points inspected on a regular basis. Loose connections and charred cables must be 3.1 Hazards when working with the removed immediately. system The progressing cavity pump was built Proper earthing must be provided whenever according to the current state of technology there is the potential for electrostatic charges. -
Page 13: Design And Function
Design and function Application and area of usage Design and function Danger! If the pump or pump unit is 4.1 Application and area of usage operated in potentially explosive Progressing cavity pumps are self-priming, atmospheres, follow the ATEX rotating displacement pumps suitable for supplemental instructions. -
Page 14: Shaft Seal
Design and function Design 4.4.3 Shaft seal The shaft is sealed by means of uncooled, cooled, or heated stuffing boxes or by means of uncooled or cooled, maintenance-free, unbalanced, single or double-acting mechanical seals. 4.4.4 Dimensions/ 76.9 dB(A) branch positions/flanges 79.3 dB(A) 1450 79.3 dB(A) -
Page 15: Non-Ionizing Radiation (Emc)
Design and function Pump unit design 4.5 Pump unit design 4.5.1 Drive Driven by electric motors with or without explosion protection, gear motors, or variable gear motors. Other drive types, such as with a V-belt, are possible. 2701 75.2 dB(A) 4.5.2 Shaft coupling and safety 5001 77.4 dB(A) -
Page 16: Transport, Storage, And Disposal
Transport, storage, and disposal Packaging 5.3 Preserving progressing cavity Transport, storage, and disposal pumps and placing them into storage 5.1 Packaging Observe the graphical symbols on the 5.3.1 Preserving packaging. The pump’s suction and pressure sides and Notice! auxiliary connections must be closed with Not necessary with stainless plugs during transport and storage. -
Page 17: Removing Preservative
Transport, storage, and disposal Preserving progressing cavity pumps and placing them into storage • Choose cleaning agents appropriate for the area of usage ( Cleaning agents, Notice! page 12). The elastomer stator in the • Dispose of preservatives according to local progressing cavity pump is regulations. -
Page 18: Cleaning Agent
Transport, storage, and disposal Disposal 5.3.5 Cleaning agent Operational range Cleaning agent Food and drinking water Such as spirits, Ritzol 155, highly alkaline soap base, steam jets (for individual parts only). Miscellaneous Cleaning ether, cleaning solvent, diesel fuel, petroleum, alkaline cleaner Tab. -
Page 19: Installation And Connection
Installation and connection Setting up the pump 6.2.2 Characteristics of a concrete Installation and connection foundation 6.1 Setting up the pump The foundation must be horizontal, even, and clean and fully absorb the foundation load. Pumps can be installed horizontally or vertically, with the bearing pointing upward. -
Page 20: Mortaring The Base Plate
Installation and connection Base plate • If major deviations are found, loosen 6.2.5 Mortaring the base plate the base plate attachment and remove ► After aligning the base plate on the the tension by refilling. concrete foundation, use a non-shrinking 6.4 Coupling mortar compound to mortar the entire length of the base plate. -
Page 21: Assembling Pump And Drive
Installation and connection Assembling pump and drive • Lay the straightedge over both 1. Apply a very thin layer of molybdenum disulfide (such as Molykote) to the halves of the coupling. ends of the pump and drive shaft; • If there is a light gap at the outer insert keys. -
Page 22: Space Requirement For Maintenance And Repair
Installation and connection Laying the pipes 6.6.3 Cleaning the pipes before Caution! installation Excessive tightening will destroy It is essential to flush and clean the suction- the pump’s antifriction bearing. side pipes, gate valves, and valves before Observe our separate “V-belt” installing the pump. -
Page 23: Safety And Inspection Equipment
Installation and connection Safety and inspection equipment 6.7 Safety and inspection 6.7.3 Electrical connections equipment Caution! 6.7.1 Pressure and vacuum gauges A professional electrician must Attach a pressure gauge to the pressure line attach the coupled drive motor’s and a vacuum gauge to the suction line. power supply cable in accordance with the connection diagram 6.7.2 Safety device in the pressure... -
Page 24: Operation
Operation Preparing for initial start-up • P04/P14 = 0 to 0.5 bar Operation (flushing and buffering liquid, Section 7.1.3 page 19). 7.1 Preparing for initial start-up • 7.1.1 Filling the pump with liquid Supplying the single-acting, unbalanced mechanical seal with throttle ring Caution! (versions G0S/ G1S and G0T/G1T). -
Page 25: Quality And Properties Of The Flushing/Buffering And Quench Liquids
Operation Preparing for initial start-up The buffering liquid pressure must be approximately 1.5 to 2 bar above the pressure ► Supplying the cooled or heated stuffing in the suction casing. The flow volume must be box casing and/or the stator and/or the regulated so that the outlet temperature does suction casing (jacketed casing) with not exceed approximately 60 °... -
Page 26: Bringing The Pump Into Operation
Operation Bringing the pump into operation 7.3 Taking the pump out of operation Caution! The pump’s direction of rotation 7.3.1 Stoppage must match the “n” directional arrow on the pump’s nameplate. ► Switch the motor off. Improper direction of rotation can 7.3.2 Measures for longer periods damage the pump! of downtime... -
Page 27: Maintenance Cycles And Intervals
Maintenance cycles and intervals Maintenance cycles and intervals Maintenance may be necessary for the following parts: rotor + stator: Wear to the rotor and/or stator is manifested in the form of lower pump capacity and lower pressure. Maintenance can be planned when this is noticed, i.e. -
Page 28: Maintenance
K3N-30 Universal joints must be lubricated with SKF grease LGMT3 K3K-30 ALLWEILER special joint oil of type B or oil Tab. 8 Overview of antifriction bearing grease ET1510 ISO 460 from Tribol Lubricants GmbH of Mönchengladbach, Germany; if the pump is... -
Page 29: Shaft Seal
Maintenance Maintenance Installing the packing rings Relubrication Relubrication is performed via lubrication Caution! nipple (119) screwed into bearing cover (110). Use only packing rings that meet Continue adding lubrication until the old grease the pump’s required operating escapes at the bearing cover (131) ( conditions! sectional drawings on pages 43, 44, 45, 46, 47, 48 and 49). -
Page 30: Mechanical Seal
Maintenance Maintenance Bringing the stuffing box into operation after re-packing Tighten the stuffing box only slightly before bringing it into operation. When the pump starts, a leak rate of 50 to 200 drops per minute is permitted. During the running-in process of approximately 30 minutes, tighten the stuffing box gland (203) incrementally via the hexagon nuts (202) to set a minimum leak of 2 to 20 drops per minute. -
Page 31: Packing Ring Dimensions ( Section 9.1.4), Lubrication
Maintenance Maintenance 9.1.7 Packing ring dimensions ( section 9.1.4), lubrication amounts for joint ( section 9.1.2), storage ( section 9.1.3), and flushing liquid flow rate ( section 7.1.2) Pump size AE1F 1003 3003 5503 1603 AE1L 1001 2701 5001 1451 AE1E 1450 2700... -
Page 32: Maintenance
Maintenance Disassembly and assembly instructions 2. All blocking devices in the feed and 10 Maintenance pressure lines must be closed. 10.1 Disassembly and assembly Be certain that the pump is instructions pressureless. Trained customer service technicians are available upon request for assembly and repair 3. -
Page 33: Fig. 9 Removing The Joint Clamp
Maintenance Disassembly and assembly instructions Remove the rotor and the rotor-side joint after removing the stator (402) Section 10.1.2 page 26. 1. Remove hexagon nuts (607), serrated washers (608), and hexagon screws (606). 2. Pull off suction casing (505) over the rotor (401). -
Page 34: Removing The Universal Joint Shaft And The Drive-Side Joint
Maintenance Disassembly and assembly instructions 6. Screw out hexagon screw (139) and 10.1.4 Removing the universal joint remove bearing cover (131) with seal shaft and the drive-side joint (132). For the positions of referenced parts 7. Screw off the bearing nut (116) from sectional drawings on pages 43, 44, 45, 46, the drive shaft (118). -
Page 35: Removing The Mechanical Seal, Single-Acting
Maintenance Disassembly and assembly instructions 4. If your version has a shaft sleeve, remove the shaft sleeve (206) and O- Notice! ring (115) from the drive shaft (118). To avoid damaging the counterring, be sure to pull off the casing with 10.1.7 Removing the mechanical the mechanical seal's counterring seal, single-acting... -
Page 36: Removing The Mechanical Seal, Double-Acting
Maintenance Disassembly and assembly instructions 6. Loosen threaded pins in the rotating 5. Pull off from the drive shaft (118) the part of the mechanical seal (219) and mechanical seal cover (215) with the pull mechanical seal from the drive mechanical seal's (219) product-side shaft (118). -
Page 37: Assembling The Progressing Cavity Pump
Maintenance Assembling the progressing cavity pump and (104) can be reused. Otherwise, the ball bearings must be replaced. Notice! 3. Fill ball bearings (103) and (104) with Removal of spacer rings applies antifriction bearing grease. Provide only to the sizes listed below. grease filling as described below. -
Page 38: Installing The Shaft Seal While The Drive Shaft Is Removed
Maintenance Assembling the progressing cavity pump 11. Press the shaft seal ring (112) into the clean seat of the bearing bracket (110). Notice! The sealing lip with the shaft seal ring’s hose spring must always face the side being sealed (pointing inward). -
Page 39: Installing The Mechanical Seal, Single-Acting
Maintenance Assembling the progressing cavity pump handling and extreme cleanliness are required 3. Slide the rotating part of the during installation to ensure flawless mechanical seal (219) onto the drive functionality. To facilitate installation, surfaces shaft (118). over which O-rings glide may be lubricated with silicon oil, polydiol, or lubricating soap, for Notice! example. -
Page 40: Single-Acting With Throttle Ring
Maintenance Assembling the progressing cavity pump 1. Drive the locking pin (236) into the mechanical seal cover (215). Caution! 2. Concentrically press the mechanical In order to flare the sealing lip of seal's counterring (219) with O-ring the shaft seal ring, first slide the into the mechanical seal cover (215). -
Page 41: Installing The Rotor And Rotor-Side Joint
Maintenance Assembling the progressing cavity pump 750, AE1F 1003,AED2N 560, 4. Use the hexagon screws (139) to AED1E 1200, AE.H 200 and all fasten the bearing cover (131) with larger pumps, the drive shaft (118) seal (132) to the bearing bracket (110). can also be pulled through the 5. -
Page 42: Tightening With Band-It Clamping Tool And Adapter J050
Mönchengladbach, Germany. If used in the food industry, fill with 10.2.4.1 Tightening with Band-It clamping ALLWEILER special joint oil type BL or tool and adapter J050 oil 1810/460 from Tribol Lubricants 1. Insert strip end of the joint clamp (306) GmbH of Mönchengladbach,... -
Page 43: Tightening With Clamping Tool Pok- It Ii
Maintenance Assembling the progressing cavity pump Fig. 22 Shearing off the joint clamp Fig. 20 Band-It clamping tool and adapter J050 6. Rotate the pressure screw in the clockwise direction with a screw Notice! wrench or ratchet until the joint clamp is sheared off. -
Page 44: Installing The Universal Joint Shaft And The Drive-Side Joint
Maintenance 10.3 Installing the stator Caution! For the positions of referenced parts sectional drawings on pages 43, 44, 45, 46, Make sure the joint clamp is 47, 48, and 49. properly bent so that it cannot slide back through the joint clamp seal image above). -
Page 45: Spare Parts
The parts labeled in the index of parts can be used as spare/reserve parts. Caution! For safety reasons, stock and use only original spare parts provided by Allweiler. Refer to the information provided under Section 2.7 ( page 5)! When ordering spare or reserve parts, always provide the following information: •... -
Page 46: Index Of Spare Parts And Recommended Spare/Reserve Parts
Spare parts Index of spare parts and recommended spare/reserve parts 11.1 Index of spare parts and recommended spare/reserve parts Legend: R = large repair kit r = small repair kit Part No. Description Repair kit Quantity Remarks Spacer sleeve Groove ball bearing Angular-contact ball bearing Bearing grease Bearing bracket... - Page 47 Spare parts Index of spare parts and recommended spare/reserve parts Part No. Description Repair kit Quantity Remarks Gland packing R, r Flushing ring Seal chamber ring Screw plug Joint tape Mechanical seal casing Mechanical seal lid O-ring Mechanical seal Locking pin Shaft seal ring Throttle ring O-ring...
- Page 48 Spare parts Index of spare parts and recommended spare/reserve parts Part No. Description Repair kit Quantity Remarks Seal Stud bolt Hexagon nut Reducing flange O-ring Washer Nameplate Round head grooved pin Information plate “Start-up” Information plate “Suction” Information plate “Pressure” Hexagon head screw Hexagon nut Serrated lock washer...
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Page 49: Sectional Drawing For Series Ae1F, Ae1L, Ae1E, Ae2E, Ae1N, Ae2N, Ae4N, Aed1E, Aed2N; Id Construction Type
Spare parts Sectional drawing for series AE1F, AE1L, AE1E, AE2E, AE1N, AE2N, AE4N, AED1E, AED2N; ID construction type 11.2 Sectional drawing for series AE1F, AE1L, AE1E, AE2E, AE1N, AE2N, AE4N, AED1E, AED2N; ID construction type Fig. 24 Sectional drawing for series AE1F, AE1L, AE1E, AE2E, AE1N, AE2N, AE4N, AED1E, AED2N;... -
Page 50: Sectional Drawings Of Shaft Seals
Spare parts Sectional drawings of shaft seals 11.3 Sectional drawings of shaft seals Fig. 25 P02 Stuffing box with flushing ring Fig. 26 P03 stuffing box with internal seal chamber ring Fig. 27 P04 stuffing box with external seal chamber ring Fig. -
Page 51: Section Drawings For Series Ae1+1H, Ae2+2H, Ae2+2V, Ae4+4V; Id Construction Type
Spare parts Section drawings for series AE1+1H, AE2+2H, AE2+2V, AE4+4V; ID construction type 11.4 Section drawings for series AE1+1H, AE2+2H, AE2+2V, AE4+4V; ID construction type Fig. 32 Sectional drawings for series AE1+1H, AE2+2H, AE2+2V, AE4+4V; ID construction type 760.0002 GB - 150 500 BA-2011.11 Series AE1F, AE1L, AE.E, AE.N, AE.H, AE.V, AED1E, AED2N... -
Page 52: Sectional Drawings For Series Ae2H, Ae4H; Id Construction Type
Spare parts Sectional drawings for series AE2H, AE4H; ID construction type 11.5 Sectional drawings for series AE2H, AE4H; ID construction type Fig. 33 Sectional drawings for series AE2H, AE4H; ID construction type BA-2011.11 760.0002 GB - 150 500 Series AE1F, AE1L, AE.E, AE.N, AE.H, AE.V, AED1E, AED2N ID, ZD construction types... -
Page 53: Sectional Drawing For Series Ae1N, Ae2N; Zd Construction Type
Spare parts Sectional drawing for series AE1N, AE2N; ZD construction type 11.6 Sectional drawing for series AE1N, AE2N; ZD construction type Fig. 34 Sectional drawing of series AE1N, AE2N; ZD construction type 760.0002 GB - 150 500 BA-2011.11 Series AE1F, AE1L, AE.E, AE.N, AE.H, AE.V, AED1E, AED2N ID, ZD construction types... -
Page 54: Sectional Drawing For Series Ae1+1H, Ae2+2H; Zd Construction Type
Spare parts Sectional drawing for series AE1+1H, AE2+2H; ZD construction type 11.7 Sectional drawing for series AE1+1H, AE2+2H; ZD construction type Fig. 35 Sectional drawings of series AE1+1H, AE2+2H; ZD construction type BA-2011.11 760.0002 GB - 150 500 Series AE1F, AE1L, AE.E, AE.N, AE.H, AE.V, AED1E, AED2N ID, ZD construction types... -
Page 55: Sectional Drawing For Series Ae2H, Ae4H; Zd Construction Type
Spare parts Sectional drawing for series AE2H, AE4H; ZD construction type 11.8 Sectional drawing for series AE2H, AE4H; ZD construction type Fig. 36 Sectional drawings of series AE2H, AE4H; ZD construction type 760.0002 GB - 150 500 BA-2011.11 Series AE1F, AE1L, AE.E, AE.N, AE.H, AE.V, AED1E, AED2N ID, ZD construction types... -
Page 56: Causes And Removal Of Operational Faults
Causes and removal of operational faults 12 Causes and removal of operational faults Discuss with the manufacturer any disturbances not contained in the following table or that cannot be traced to the causes listed below. Each possible disturbance is labeled with a letter in the table below. - Page 57 Causes and removal of operational faults Operational disturbances Causes and removal High adhesion between rotor and stator in new condition after long period of downtime Use tool to manually turn pump. Reference arrow on pump to check direction of rotation; reverse polarity of motor if necessary.
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Page 58: Clearance Certificate
Clearance certificate 13 Clearance certificate Fig. 37 Clearance certificate BA-2011.11 760.0002 GB - 150 500 Series AE1F, AE1L, AE.E, AE.N, AE.H, AE.V, AED1E, AED2N ID, ZD construction types... -
Page 59: Declaration According To Ec Machinery Directive
Declaration according to EC machinery directive 14 Declaration according to EC machinery directive Declaration of conformity according to EC machinery directive Notice! The following declaration contains neither serial numbers nor signatures. The original declaration with the name of the documentation officer and signatures is included with each pump. - Page 60 Hiermit erklären wir, / We hereby declare / Par la présente, nous déclarons Allweiler AG, Postfach 200123, 46223 Bottrop, Tel. +49 (0)2045-966-60, Fax. +49 (0)2045 966-679 dass die Maschine / that the machine / que le machine Ident Nr. / Ident no / Nº d'ident Benennung / Designation / Désignation...
- Page 61 760.0002 GB - 150 500 BA-2011.11 Series AE1F, AE1L, AE.E, AE.N, AE.H, AE.V, AED1E, AED2N ID, ZD construction types...
- Page 62 BA-2011.11 760.0002 GB - 150 500 Series AE1F, AE1L, AE.E, AE.N, AE.H, AE.V, AED1E, AED2N ID, ZD construction types...
- Page 63 760.0002 GB - 150 500 BA-2011.11 Series AE1F, AE1L, AE.E, AE.N, AE.H, AE.V, AED1E, AED2N ID, ZD construction types...
- Page 64 Subject to technical changes! ALLWEILER AG Postfach 20 01 23 46223 Bottrop Kirchhellener Ring 77-79 46244 Bottrop Germany Tel. +49 (0)2045 966-60 Fax +49 (0)2045 966-679 E-mail: service@allweiler.de Internet: http://www.allweiler.com Edition: BA-2011.11 VM-No.: 760.0002 GB Print No.: 150 500...
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