VERDER Packo ZP Series Instruction Manual
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VERDER Packo ZP Series Instruction Manual

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  • Page 1 Instruction manual...

  • Page 2: Table Of Contents

    CONTENTS GENERAL General Information Manufacturer Copyright Declaration of conformity Intended Use Type designation Sound pressure level Construction Packaging & Transport 1.10 Storage SAFETY DO’S and DON’TS ATEX safety measures INSTALLATION Installation Connection of the motor Connecting the mechanical seal flush Start Up CHECK THE PUMP ROTATION Principle of operation...

  • Page 3: General

    1 GENERAL 1.1 GENERAL INFORMATION Thank you for purchasing PACKO products! This manual for the ZP series Circumferential Piston Pumps describes safe and appropriate operation during operating and in all life cycles. This manual contains instructions for installation, operation, disassembly and assembly, maintenance procedures and troubleshooting.

  • Page 4: Declaration Of Conformity

    1.4 DECLARATION OF CONFORMITY Declaration of conformity according to annex IIA of the “Machinery” Directive 2006/42 EC Packo Inox Ltd Cardijnlaan 10 B-8600 DIKSMUIDE BELGIUM confirm that the Packo pump type ……........, with serial number ......fully complies with the Directive Machinery and with the (harmonised) standard EN 809, ENISO12100.

  • Page 5: Intended Use

    1.5 INTENDED USE The pump should only be used for pumping the media it was selected for and within the limits specified in the technical datasheets. Any other application beyond the intended use or conversion of the pump without written agreement with the manufacturer shall be deemed to be not in accordance with the intended use.

  • Page 6: Sound Pressure Level

     4: number of poles of the motor Mat. Code: (BW-120) D37SSVQ  BW: rotor type (BW = bi-wing)  120: temperature class of the pump (Deg. C)  D: type of couplings (D = DIN 11851, B = BSP, E = DIN 2642, F = DIN 2576, R = RJT, S = SMS, I = IDF, T = Tri-Clamp ISO2852, M = Tri-clamp ASME BPE, O = Tri-clamp ISO, N = ANSI flanges, V = DIN 11864-1, A = DIN 11864-2) ...
  • Page 7 Example Layout of pumps with complete unit ① Base plate, ② Drive unit, ③ Coupling & coupling guard, ④ Gearbox, ⑤ Rotor case with inlet & outlet ports, ⑥ Front cover...

  • Page 8: Packaging & Transport

    1.9 PACKAGING & TRANSPORT ZP series are shipped in non-returnable wooden packaging. Unpack the pump/unit upon delivery and inspect it for visible transport damage. Any damage occurred during the transport has to be immediately reported to the transport agent after receipt of the consignment. Do not put the damaged products into operation. The pumps need to be transported and secured with care to ensure no damage is caused.

  • Page 9: Safety

    2 SAFETY 2.1 DO’S & DON’TS DO read and understand these instructions before installing or using the pump. DO use PACKO spare parts when replacing a component of the pump. DO NOT service the pump while it is running. DO NOT place the pump in an application where the service ratings are exceeded. DO NOT modify the pump.

  • Page 10: Atex Safety Measures

    2.2 ATEX SAFETY MEASURES Risk Dry running of mechanical Leakage Pump seal (inflammable liquid can come into the type (overheated seal faces are an atmosphere) Liquid ignition source) ignitable • Flushed mechanical seal No danger liquid • or flow monitoring to be •...

  • Page 11: Installation

    3 INSTALLATION 3.1 INSTALLATION 1. The mounting surface should be flat and level. 2. Ensure at least 0.5 m clearance around the pump. 3. Normally, pump and drive unit are assembled on a baseplate. If you want another configuration, feel free to contact PACKO. 4.

  • Page 12: Connecting The Mechanical Seal Flush

    technician is responsible for complying with the regulations relating to electrical compatibility in the country where the pump is installed. The voltage and the frequency stated on the name plate of the motor must be observed. (Tolerance of 5 % for the voltage, and 1 % for the frequency.) For pumps whose power exceeds 7.5 kW, special starting provisions must be provided (star-delta starter, soft starter, or starting with frequency converter).

  • Page 13: Check The Pump Rotation

    2. Air in the suction inlet line. 3. Pumping temperature is too high. 4. Pump is oversized. 4 CHECK THE PUMP ROTATION 4.1 PRINCIPLE OF OPERATION The pumps are of the positive displacement rotary type with lobed rotors. The volume at the inlet increases when the rotors rotate and the product is drawn into the pump.

  • Page 14: Operation

    5 OPERATION 5.1 TROUBLESHOOTING Problem Cause Solution Pump not rotating Interruption of electrical power. Reset circuit breaker, check fuses. Key sheared or missing. Replace. Coupler or belts are not connected. Replace or adjust. Pump shaft or gears sheared. Replace. Wrong rotation. Reverse.

  • Page 15: Cleaning

    5.2 CLEANING 1. Before cleaning the pump, wear rubber gloves and protective glasses. 2. During CIP and SIP process, do not touch the pump and pipelines. 3. Ensure velocity rate of the CIP solutions is adequate to clean entire circuit. For most applications a velocity of 1.5 m/sec is sufficient.

  • Page 16: Maintenance

    6 MAINTENANCE 6.1 ROTOR CASE DISASSEMBLY Prior to removal of the pump, the shut-off valves in the suction and discharge pipe work must be closed. If there is any risk that product may be hardened, crystallized or frozen in the pump, it should be thoroughly drained and cleaned immediately after use.
  • Page 17 Clean and examine all of the pump components for damage. Replace damaged components as required. PACKO recommends replacing all the wetted elastomers during reassembly. If you want to replace the seal ring only, you can remove the old one & insert the new one easily just after removing the rotors without dismantling the rotor case.

  • Page 18: Inspection

    6.2 INSPECTION While performing standard maintenance or cleaning, check for signs of damage or extreme wear. A simple inspection may show signs of a problem long before it becomes a serious issue. Detection of such problems can avoid costly repairs and reduce down time. 1.

  • Page 19: Seal Maintenance

    6.3 SEAL MAINTENANCE Check & inspect all components of the seal replacement kit carefully whether there is any damage or defect before installing. If any chipping, crack or scratch found during inspection, do not reuse them and replace the damaged one. Below shows the Single mechanical seal (Figure 9), Double mechanical seal (Figure 10) and PTFE Triple lip seal with ceramic coated sleeve (Figure 11).
  • Page 20 Single Mechanical Seal Maintenance Remove the Seal ring from the rotor case & rotor and inspect them. If any seal is damaged, do not re-use and replace it. Clean both shaft ends and the rotor case before assembling. After rotor case assembly, push the replacing NEW Seal ring into the rotor case O-ring and turn it until the seal pins on the seal body fit Fig.
  • Page 21 Double Mechanical Seal Maintenance Remove the Seal ring from the rotor case & rotor (shown in Figure 17) and inspect them. If any seal is damaged, do not re-use and replace it. Clean both shaft ends and the rotor case before assembling. Push the replacing NEW Seal ring into the rotor case O-ring and turn until it fits into the seal pins on the seal body after Rotor Case Assembly on chapter 6.4.
  • Page 22 Triple Lip Seal Maintenance After the rotor case has been removed (Figure 6), pull out and remove the Ceramic coated sleeves from the shafts and inspect them. If any of them is damaged do not re-use and replace them. Clean both shaft ends and the rotor case before assembling. Slide &...

  • Page 23: Rotor Case Assembly

    6.4 ROTOR CASE ASSEMBLY Before installing the rotor case (31) to the gearbox (1A), make sure to clean the surface of the rotor case & gearbox and make sure to put the shims between rotor case and gearbox as originally. Assemble the rotor case (31) onto the gearbox (1A) and secure the four hexa-nuts (46) with reference of below torque set value.
  • Page 24 Insert the rotors along the shaft and make sure that the seal rings do not fall out of their seats in the rotors. Fig. 28 Tighten the rotor bolts with the rotor bolt extraction tool firmly. Be sure not to make any bur on the rotor bolt groove during this process.

  • Page 25: Rotor Clearance

    6.5 ROTOR CLEARANCE Rotor clearance must be precisely maintained to provide maximum pumping efficiency and to prevent contact between rotors, rotor case, and front cover during operation. If pumping efficiency is lower than expected or if parts contact has occurred during operation (Within rated differential pressure), check the rotor clearances and adjust, if incorrect.

  • Page 26: Rotor Timing

    6.6 ROTOR TIMING Rotor timing is critical for the pump operation and must be precisely maintained to provide maximum pumping efficiency and to prevent contact between rotors during operation. If pumping efficiency is below expectations, or if rotors contact during operation (within rated differential pressure), check the rotor timing and adjust if incorrect.
  • Page 27 Fig. 35 7. Reattach the gears to the shafts with the locknut and bend one lip of the locking lip into a groove of the locknut.

  • Page 28: Gearbox Maintenance

    6.7 GEARBOX MAINTENANCE Gearbox Disassembly 1. Remove the drain plug and drain the oil. Remove the shaft key (7) on the drive shaft and gearbox cover bolts (6) from the rear cover (4). Pull the cover off the drive shaft extension. If the cover is stuck, use a soft mallet carefully to loosen it.
  • Page 29 Or pull out the drive & idle shafts by hitting with a soft mallet the rear-end of each shaft on the gasket face of the gearbox. Fig. 40 9. Remove the bearings and spacers (16) together from the shafts by pressing the shaft out of them. Or remove bearings by puller shown in Figure 41.
  • Page 30 Gearbox Assembly 1. Clean and lubricate the front & rear bearing areas of the drive & idle shafts with oil. Fit the front bearing, spacer and rear bearing on the shaft sequentially by press (or heat up to 120 ℃ (250F)). Position the gearbox (1) with wet end side facing up and be sure to support the gasket face (downside) carefully in order not to damage it.
  • Page 31 4. Place the gear, lock washer (12) and lock nut (12-1) sequentially onto the shafts and hand tighten. In order to ensure proper rotor timing the gears must be installed along with the rotors. Slide the gears on the shafts aligning the slot on the gear with the gear key.

  • Page 32: Lubrication

    6.8 LUBRICATION Pump bearings and gear should run in an oil bath. Replacement of these bearings and gear wheels is recommended after 20,000 hours of operation. However, shorter change intervals required for particularly difficult operating conditions, such as: High temperature variations High pressure fluctuations The oil in the gearbox is recommended to be changed once a year or every 2,000 operating hours.

  • Page 33: Technical Information

    7 TECHNICAL INFORMATION 7.1 TECHNICAL DATA - Maximum outlet pressure: Pump type Max outlet pressure (bar) Temperature Range: depending on temperature class of the rotors: max 120°C or max 150°C, see nameplate. For ATEX pumps, the maximum temperature of the pumped liquid is 108°C.

  • Page 34: Exploded Views

    8 EXPLODED VIEWS 8.1 EXPLODED VIEW / ZP015 & ZP018...
  • Page 35 All orders for repair parts must contain the following: 1. Complete model number (located on nameplate). 2. Pump serial number (located on nameplate). 3. Description and position number from the exploded view. SINGLE MECHANICAL SEAL & TRIPLE LIP SEAL / ZP015 & ZP018 Single Mech.
  • Page 36 DOUBLE MECHANICAL SEAL / ZP015 & ZP018 O-RING SEAL & DOUBLE O-RING SEAL / ZP015 & ZP018 O-ring Seal Double O-ring Seal...

  • Page 37: Exploded View Zp030, Zp060, Zp130

    8.2 EXPLODED VIEW / ZP030, ZP060, ZP130...
  • Page 38 SINGLE MECHANICAL SEAL & TRIPLE LIP SEAL / ZP030 Single Mech. Seal Triple Lip Seal...
  • Page 39 DOUBLE MECHANICAL SEAL / ZP030 O-RING SEAL & DOUBLE O-RING SEAL / ZP030 Double O-ring Seal O-ring Seal...
  • Page 40 SINGLE MECHANICAL SEAL & TRIPLE LIP SEAL / ZP060 Single Mech. Seal Triple Lip Seal DOUBLE MECHANICAL SEAL / ZP060...
  • Page 41 O-RING SEAL & DOUBLE O-RING SEAL / ZP060 O-ring Seal Double O-ring Seal...
  • Page 42 SINGLE MECHANICAL SEAL & TRIPLE LIP SEAL / ZP130 Single Mech. Seal Triple Lip Seal...
  • Page 43 DOUBLE MECHANICAL SEAL / ZP130...
  • Page 44 O-RING SEAL & DOUBLE O-RING SEAL O-ring Seal Double O-ring Seal...

This manual is also suitable for:

Zp015 seriesZp018 seriesZp030 seriesZp060 seriesZp130 series

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