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Progressive Cavity Pump
Operating instructions
Version
BA-2020.05 en-US
176-982/0
ID-No.
260371
Series:
AE(B).E, AE(B).F, AE(B).H,
AE(B).L, AE(B).N, AE.V,
AED(B).E, AED(B).N
Designs:
DE, ID, IE, RG, ZD, ZE
ALLWEILER GmbH
Postfach 200123
Kirchhellener Ring 77-79
46244 Bottrop
Germany
Phone: +49 (0) 2045-966-60
Fax: +49 (0) 2045 966-679
E-mail: service@allweiler.de
Internet: http://www.allweiler.com
We reserve the right to make technical changes.
Read carefully before use.
Retain for future use.
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Table of Contents
Troubleshooting
Related Manuals for Allweiler AEB.E Series
Summary of Contents for Allweiler AEB.E Series
- Page 1 Operating instructions Series: AE(B).E, AE(B).F, AE(B).H, AE(B).L, AE(B).N, AE.V, AED(B).E, AED(B).N Designs: DE, ID, IE, RG, ZD, ZE Version BA-2020.05 en-US ALLWEILER GmbH 176-982/0 Postfach 200123 ID-No. 260371 Kirchhellener Ring 77-79 46244 Bottrop Germany Phone: +49 (0) 2045-966-60 Fax: +49 (0) 2045 966-679 E-mail: service@allweiler.de...
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Page 2: Table Of Contents
Table of contents Table of contents About this document ....... 5.2.2 Fastening the pump unit . - Page 3 Table of contents 7.2.4 Joints with oil lubrication ..... 26 Fig. 10 Installation with foundation ....16 7.2.5 Packing gland .
- Page 4 Table of contents Tab. 11 Designation of components according to part Tab. 40 Total volume and residual liquid quantity numbers ........37 AED1E .
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Page 5: About This Document
About this document About this document This manual • Is part of the pump • Applies to the afore-mentioned pump series • Describes safe and appropriate operation during all oper- ating phases Target groups Target group Duty Operating company Keep this manual available at the site of operation of the system, including for later use. -
Page 6: Warnings And Symbols
About this document Warnings and symbols Warning Risk level Consequences of disregarding the warning Immediate acute risk Death, serious bodily harm DANGER Potential acute risk Death, serious bodily harm Potentially hazardous situation Minor bodily harm CAUTION Potentially hazardous situation Material damage NOTE Tab. -
Page 7: Safety
Safety Safety The manufacturer does not accept any liability for damage General safety instructions resulting from disregard of the entire documentation. Observe the following regulations before carrying out any work. Intended use 2.2.1 Product safety • Only use the pump for pumping the agreed pumped media The pump has been constructed according to the latest tech- (→... -
Page 8: Obligations Of Personnel
(→ ATEX additional instructions). gressive cavity pumps). 2.3.2 Hazardous pumped liquids • When using combustion engines, consult Allweiler. • Follow the safety regulations for handling hazardous sub- • For pumps with stub shaft, connect drive system and pump stances when handling hazardous (e.g. hot, flammable, directly with stub shaft (special drives required) poisonous or potentially harmful) pumped liquids. -
Page 9: Layout And Function
Pump type code (example) Posi- Meaning tion Series Product Fig. 1 Nameplate (example with explosion Allweiler progressive cavity pump in a protection mark) bearing pedestal design Explosion protection mark Allweiler progressive cavity pump, close-coupled Pump equipment number Pump type Number of stages Direction of rotation or flow... -
Page 10: Layout
Layout and function Layout Example representation of 2 variants. Further variants are described in the appendix (→ 9.1.2 Sectional drawings, Page 39). 3.2.1 Base version 10 11 Fig. 3 Layout – AE, ID design Pressure side Bearing Suction side/suction casing Stator Universal joint shaft Bearing pedestal... -
Page 11: Rg Version (Open-Feed Version With Internal Gearbox Mounting)
Layout and function 3.2.2 RG version (open-feed version with internal gearbox mounting) 10 11 10 12 13 Fig. 4 Layout – AE, RG design (open-feed version with internal gearbox mounting) Pressure side Suction side/suction casing Spur gears Bearing pedestal Stator Universal joint shaft Rotor Stub shaft... -
Page 12: Auxiliary Systems
Layout and function Auxiliary systems Types of setup The following types of setup are possible: 3.6.1 Sealing system – Horizontal, dry Sealing systems in various designs are available from the – Vertical dry, wall installation (only permissible if drive manufacturer upon consultation. and bearing at top) 3.6.2 Heating and cooling system (optional) -
Page 13: Transport, Storage And Disposal
Transport, storage and disposal Transport, storage and disposal Transport Weight specifications (→ order data sheet). 4.1.1 Unpacking and inspection on delivery 1. Unpack the pump/aggregate on delivery and inspect it for transport damage. 2. Report any transport damage to the manufacturer immedi- ately. -
Page 14: Storage
Transport, storage and disposal Storage Disposal Plastic parts can be contaminated by poisonous or radioac- NOTE tive pumped liquids to such an extent that cleaning will be insufficient. Material damage due to inappropriate storage! Treat and store the pump properly. For a longer storage time, dismantle the elastomer stator WARNING and store it in dark film at -10 to 25 °C. -
Page 15: Setup And Connection
Setup and connection Setup and connection For pumps in explosion-hazard areas (→ ATEX additional 5.1.4 Preparing the foundation and surface instructions). Setup options: – With concrete foundation – With steel foundation frame NOTE Make sure the foundation and surface meet the following Material damage due to distortion or passage of electrical conditions: current in the bearing! -
Page 16: Installation On A Foundation
Setup and connection Installation on a foundation 5.2.2 Fastening the pump unit The damping behavior is improved by filling the base plate with mortar grout. When filling, isolate any present adjust- NOTE ing screw for the engine height adjustment. Material damage due to distortion of the base plate! 1. -
Page 17: Installing The Motor
Setup and connection Installing the motor 5.3.3 Pump with belt drive Depending on the version, belt guard or parts thereof Only necessary if the pump unit is assembled on site. are already attached to the pump unit when the motor is installed. -
Page 18: Specifying Nominal Diameters
Setup and connection 5.4.2 Specifying nominal diameters 5.4.5 Discharging leaks Keep the flow resistance in the pipes as low as possible. WARNING Risk of injury and poisoning due to hazardous pumped 1. Make sure the nominal suction pipe diameter is ≥ as pos- liquids! sible to the nominal suction branch diameter. -
Page 19: Connecting The Pipes
Setup and connection Connecting the pipes 5.5.5 Inspection for stress-free pipe connections Piping installed and cooled down 5.5.1 Keeping the piping clean NOTE NOTE Material damage due to impurities in the pump! Material damage due to distorted pump casing Make sure no impurities or foreign particles enter the pump. Ensure that all pipes are stress relieved when connected to the pump. -
Page 20: Aligning The Coupling Precisely
Setup and connection Aligning the coupling precisely 3. Measure the gap with a feeler gauge (2): – Permissible gap (→ setup drawing) Applies to base plate version with coupling – Use the feeler gauge to measure the gap (A) between the coupling halves. -
Page 21: Aligning The Motor
Setup and connection Aligning the motor Applies to base plate version with coupling Alignment options: – With sets of shims – With adjusting screws 1. Align the motor so that the coupling halves are exactly in line and fit shims if necessary. 2. -
Page 22: Operation
Operation Operation For pumps in explosion-hazard areas (→ ATEX additional 6.1.4 Filling pump instructions). Venting is not necessary. Preparing initial start-up DANGER 6.1.1 Identifying the pump type The pump versions vary e.g. with regard to the design, Danger to life due to hazardous media! bearing lubrication, type of shaft seal and auxiliary operat- Use protective equipment when carrying out any work on ing systems. -
Page 23: Checking The Sense Of Rotation
Operation DANGER 6.1.6 Checking the sense of rotation If the correct sense of rotation has already been determined Risk of injury and poisoning due to pumped liquid spray- when the pump is spinning, it is no longer necessary to check ing out! the sense of rotation. -
Page 24: Shutting Down The Pump
Operation Shutting down the pump Behavior of the Duration of shutdown (depending pumped liquid on process) WARNING Short Long Solids Flush the Flush the Risk of injury and poisoning due to hazardous pumped sedimenting pump. pump. liquids! Safely collect any leaking pumped liquid and dispose of it Solidifying/ Heat up or Empty the... -
Page 25: Maintenance
Maintenance Maintenance For pumps in explosion-hazard areas (→ ATEX additional Maintenance instructions). Service life of the antifriction bearings for operation within Trained service technicians are available for fitting and the permissible operating range: > 2 years repair work. Present a pumped medium certificate (DIN Intermittent operation, high temperatures, low viscosities safety data sheet or safety certificate) when requesting and aggressive ambient and process conditions reduce the... -
Page 26: Antifriction Bearings Lubricated With
Maintenance 7.2.1 Antifriction bearings lubricated with grease 7.2.5 Packing gland When set up vertically, the bearings are lubricated for life. Replacing the packing gland The packing gland must always leak slightly to carry the Applies to ID, ZD and RG designs. frictional heat away. -
Page 27: V-Belt Drive
Maintenance Dismounting 7.2.8 V-belt drive Service V-belt drive according to manufacturer’s specifica- tions (→ manufacturer’s specifications). DANGER 7.2.9 Motor Risk of injury due to running pump! Do not touch the running pump. Service motor according to manufacturer’s specifications (→ manufacturer’s specifications). Do not carry out any work on the running pump. -
Page 28: Returning The Pump To The Manufac
Maintenance 7.3.1 Returning the pump to the manufacturer 7.3.2 Dismounting Pump depressurized Pump depressurized Pump completely empty Pump completely empty, flushed and decontaminated Electrical connections disconnected and motor secured Electrical connections disconnected and motor secured against being switched on again against being switched on again Pump cooled down Pump cooled down... -
Page 29: Installing
Maintenance Installing Ordering spare parts Reinstall the components concentrically, without canting, For trouble-free replacement in the event of faults, we rec- in accordance with the marks applied. ommend keeping entire insert units or spare pumps avail- able on site. The application guidelines described in DIN 24296 recom- WARNING mend provisions for two years of continuous use Risk of injury due to heavy components! -
Page 30: Troubleshooting
Troubleshooting Troubleshooting Pump malfunctions If malfunctions occur which are not specified in the following table or cannot be traced back to the specified causes, please consult the manufacturer. Possible malfunctions are identified by a number in the follow- ing table. This number identifies the respective cause and rem- edy in the troubleshooting list. - Page 31 Troubleshooting Malfunction number Cause Remedy – – – – Excessive amount of gas: pump is Check the cable gland. cavitating Clean/enlarge the filter. Enlarge the supply/suction pipe cross-section. – – – – Shaft seal leaky Replace the shaft seal. – –...
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Page 32: Pump Troubleshooting List
Troubleshooting Malfunction number Cause Remedy – – – – – Pumped liquid temperature too high: Increase the pump inlet pressure. pump is cavitating Lower the temperature. Consult the manufacturer. – – – – – Hydraulic parts of the pump dirty, clotted Dismount the pump. -
Page 33: Appendix
Appendix Appendix Sectional drawings 9.1.1 Part numbers and designations The marked parts are available as a repair set from the man- ufacturer:: • R = large repair set • r = small repair set Part Designation Design IE, ZE ID, ZD repair set Quantity repair set... - Page 34 Appendix Part Designation Design IE, ZE ID, ZD repair set Quantity repair set Quantity repair set Quantity Hexagon nut Spring ring Disk Screw sealing material Centering pin Worm shaft Oil level sight glass Gasket Supporting washer O-ring Hexagon head bolt Spring ring Bearing cover Bearing cover gasket...
- Page 35 Appendix Part Designation Design IE, ZE ID, ZD repair set Quantity repair set Quantity repair set Quantity Spacer sleeve Groove ball bearing Thrust bearing Bearing grease Hexagon head bolt Spring ring Bearing cover gasket Bearing pedestal Bearing cover Shaft seal ring Spacer ring Oil thrower O-ring...
- Page 36 Appendix Part Designation Design IE, ZE ID, ZD repair set Quantity repair set Quantity repair set Quantity Mechanical seal cover O-ring Mechanical seal Retaining pin Shaft seal ring Throttle ring O-ring Retaining pin Stud bolt/hexagon head bolt Sealing material Joint pin R, r R, r R, r...
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Page 37: Numbers
Appendix Part Designation Design IE, ZE ID, ZD repair set Quantity repair set Quantity repair set Quantity „Suction“ information plate „Pressure“ information plate Hexagon head bolt/stud bolt Hexagon nut Serrated washer Hexagon nut Disk Clamp bolt Support Hexagon nut Risk of injury information plate Fixing piece Hexagon nut Spacer... -
Page 38: Drawings
Appendix Additional information in sectional drawings Additional information is marked in the sectional drawings, for example regarding versions or sizes: Labels Explanation Double casing for suction casing optional Part secured with a punch Part secured with 2 punches Double-jacket casing for shaft seal optional Radial bearing for setup with shaft vertically upwards Thrust bearing for specified sizes... -
Page 39: Sectional Drawings
Appendix 9.1.2 Sectional drawings Pumps/pump units Fig. 16 AE, design ID and AEB, design IE 260371 – 176-982/0 BA-2020.05 en-US... -
Page 40: Ae, Design Zd And Aeb, Design Ze
Appendix Fig. 17 AE, design ZD and AEB, design ZE BA-2020.05 en-US 260371 – 176-982/0... -
Page 41: Ae, Dosing Pump Design
Appendix Fig. 18 AE, dosing pump design 260371 – 176-982/0 BA-2020.05 en-US... -
Page 42: Ae, Design Rg
Appendix Fig. 19 AE, design RG (version with worm on universal joint shaft) BA-2020.05 en-US 260371 – 176-982/0... -
Page 43: Ae, Design Rg (Detailed Views: Mixing Screw And Bearings Of Specific Sizes)
Appendix 109 92 14 104 Fig. 20 AE, design RG (detailed views: mixing screw and bearings of specific sizes) 260371 – 176-982/0 BA-2020.05 en-US... -
Page 44: Packing Gland With Flushing Ring (P02)
Appendix Shaft seals 90° Fig. 23 Packing gland with external lantern ring (P04) Fig. 21 Packing gland with flushing ring (P02) 212, 213 90° 90° Fig. 22 Packing gland with internal lantern ring (P03) Fig. 24 Mechanical seal, single-action (G0K and G0N) BA-2020.05 en-US 260371 –... -
Page 45: Mechanical Seal, Single-Action With Throttle Ring (G0S And G0T)
Appendix 90° 90° Fig. 25 Mechanical seal, single-action with throttle ring (G0S and G0T) Fig. 27 Mechanical seal, double-action (G0D) 212, 213 90° Fig. 26 Mechanical seal, single-action with quenching (G0Q) 260371 – 176-982/0 BA-2020.05 en-US... -
Page 46: Stator Versions
Appendix Stator versions Fig. 28 Stator versions BA-2020.05 en-US 260371 – 176-982/0... -
Page 47: Technical Specifications
Appendix Technical specifications 9.2.4 Parameters for auxiliary systems Sealing medium requirements: 9.2.1 Ambient conditions Operation under any other ambient conditions should be Medium Requirements agreed with the manufacturer. Clean water with • Compatible with the liquid and low hardness all parts touched Tempera- Relative humidity [%] Setup... -
Page 48: Lubricants
Lubrication point Lubricants Buffering medium 1.5–2.0 bar over pressure pressure in the Joints of the • ALLWEILER special joint oil suction casing universal joint shaft type B Exit Flow rate (regulation • ALLWEILER special joint oil temperature takes place via... -
Page 49: Tightening Torques
Appendix 9.2.7 Tightening torques Size Motor Differential Sound speed pressure pressure [rpm] ∆ p [bar] level Thread Tightening torque [Nm] for strength class Lp (A) [dB(A)] size A4-70 < 70 27.3 18.8 37.3 64.5 380 G 76.0 < 70 71.4 73.8 1597 1080... -
Page 50: Tab
Appendix 2-stage pumps 4-stage pumps Motor Motor Size Differential Sound Size Differential Sound speed pressure pressure speed pressure pressure [rpm] ∆ p [bar] level [rpm] ∆ p [bar] level Lp (A) [dB(A)] Lp (A) [dB(A)] < 70 < 70 71.3 71.3 76.3 75.8... - Page 51 Appendix 4+4 stage pumps Motor Size Differential Sound speed pressure pressure [rpm] ∆ p [bar] level Lp (A) [dB(A)] On request 1450 Tab. 32 Sound pressure level for 4+4 stage pumps 260371 – 176-982/0 BA-2020.05 en-US...
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Page 52: Groups
Appendix 9.2.9 Technical data for specific pump groups Below pumps are classified in pump groups based on series and size. Specific technical data for the packing gland, lubrication quantities and volumetric flow rates apply to each pump group. Series Size –... -
Page 53: Quantity
Appendix Lubricant quantities Parameter Values by pump group Oil per joint [cm – Grease per bearing 1270 2050 4070 Tab. 35 Lubrication quantities by pump group Volumetric flow rate of sealing medium Parameter Values by pump group – Volumetric flow rate 0.05 0.07 0.09... -
Page 54: Total Volume And Residual Liquid Quantity Ae2E And Aeb2E
Appendix AE2E and AEB2E Parameter Values by size [l] 1450 2700 5000 9500 Total volume 1.31 2.31 4.12 7.39 13.11 25.45 49.18 On request Residual liquid quantity 0.37 0.71 1.31 2.23 4.45 8.55 15.70 On request Tab. 41 Total volume and residual liquid quantity AE2E and AEB2E 1) Applies only for AE2E AE1N and AEB1N Parameter... -
Page 55: Total Volume And Residual Liquid Quantity Ae1+1H
Appendix AE1+1H Parameter Values by size [l] 2700 Total volume 96.80 Residual liquid quantity 15.63 Tab. 47 Total volume and residual liquid quantity AE1+1H AE2H Parameter Values by size [l] 1450 2700 Total volume 5.12 9.00 17.62 31.36 56.24 96.80 Residual liquid quantity 0.70 1.25... -
Page 56: Declaration Of Harmlessness
Every commercial company is obligated to comply with the legal regulations on work www.allweiler.de/ safety, set forth for example in Germany in the Workplace Ordinance (ArbStättV), en/sales-service/ the Accident Prevention Regulations (UVV), the Hazardous Substances Ordinance downloads (GefStoffV) and the applicable environmental regulations. -
Page 57: Declaration Of Conformity According To Ec Fig. 28 Machine Directive
The original declaration is delivered with the respective pump. EC declaration of conformity according to machine directive, appendix II A ALLWEILER GmbH, Postfach 200123, 46223 Bottrop, Tel. +49 (0)2045 966-60, Fax. +49 (0)2045 966-679 hereby declare that the pump unit/pump: Designation Equipment no. - Page 58 Appendix BA-2020.05 en-US 260371 – 176-982/0...
- Page 59 Appendix 260371 – 176-982/0 BA-2020.05 en-US...
- Page 60 Appendix BA-2020.05 en-US 260371 – 176-982/0...
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