Vogelsang IQ112 Series Operating Instructions Manual

Vogelsang IQ112 Series Operating Instructions Manual

Rotary lobe pump
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2016-09-21
*WBV.PU.004.EN*
WBV.PU.004.EN V3.2
Operating Instructions
Rotary Lobe Pump
IQ112
*WBV.PU.004.EN*
2016-09-21
WBV.PU.004.EN V3.2
1/62

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Summary of Contents for Vogelsang IQ112 Series

  • Page 1 2016-09-21 *WBV.PU.004.EN* WBV.PU.004.EN V3.2 Operating Instructions Rotary Lobe Pump IQ112 *WBV.PU.004.EN* 2016-09-21 WBV.PU.004.EN V3.2 1/62...
  • Page 2: Issuer

    © 2016 Hugo Vogelsang Maschinenbau GmbH Registered trademarks of Vogelsang Vogelsang, RotaCut, PreMix, HiFlo, ACC, CFC, BioCrack, XTill, EnergyJet, BioCut, CC series, PreMix, ProTerra and VarioCrop are registered trademarks of Hugo Vogelsang Maschinenbau GmbH. ®...
  • Page 3: Table Of Contents

    Each product is developed and built so that you can work more successfully. We call it quite simply: ENGINEERED TO WORK If you want to know more about our company or put forward requests or suggestions, a wealth of information can be found at www.vogelsang.info Table of contents Issuer ................................. 2 Table of contents ..............................
  • Page 4 Table of contents Maintenance ............................35 Buffer chamber ..........................35 8.1.1 Pressurisable buffer fluid tank ..................... 36 Buffer fluid – type ......................... 39 8.1.2 Buffer fluid – amount ........................39 8.1.3 Buffer fluid – inspection and change ................... 39 8.1.4 Draining and cleaning the buffer chamber ..................
  • Page 5 Table of contents Table of figures Fig. 1: Name plate ............................12 Fig. 2: Positions of the warning and safety labels ................... 17 Fig. 3: Transport aids ............................18 Fig. 4: Installation variants ..........................20 Fig. 5: Long suction lines ..........................22 Fig.
  • Page 6: User Information

    Read the operating instructions thoroughly. All of the points presented in these instructions must be understood and observed by those persons responsible for the installation, operation, maintenance and repair of the machine. Vogelsang does not accept any liability for damage resulting from failure to comply with these operating instructions. KEEP FOR FUTURE REFERENCE Please keep the manual ready at hand to ensure easy access to the necessary information at all times.
  • Page 7: Explanation Of Symbols

    User information Explanation of symbols The following symbols and signal words are used in this manual: If personal protective equipment is needed to work with and on the machine, that is indicated by the following symbols: Indicates that protective gloves must be worn for subsequent tasks. Indicates that protective goggles must be worn for subsequent tasks.
  • Page 8: Machine Versions Described Here

    User information Safety notes are introduced by these symbols and words: CAUTION Refers to a dangerous situation in which failure to comply with the safety note could result in light injuries. WARNING Refers to a dangerous situation in which failure to comply with the safety note could result in death or serious injuries.
  • Page 9: Ec Declaration

    Applied national standards and technical specifications: DIN EN 82079-1:2012 DIN 4844-1:2012 DIN 4844-2:2012 DIN ISO 3864-1:2012 The person authorized to compile the technical documentation is: Hugo Vogelsang Maschinenbau GmbH; Holthöge 10-14; 49632 Essen (Oldb.), Germany 49632 Essen, 2015-09-30 Harald Vogelsang (Managing Director) WBV.PU.004.EN V3.2...
  • Page 10: Specifications

    Specifications Specifications Gemeinde Max. speed: 900 min Max. differential Theoretical IQ112 series pressure** operating torque*** Displacement Theoretical volume flow* Size [l/min] [bar] [Nm] 1.02 55.08 1.44 1298 77.88 All values refer to the theoretical volume flow. The actual volume flow is lower; it depends on the operating conditions in each case.
  • Page 11: Material Description For Rotary Lobes

    (pure material) Table: Material description  consult Vogelsang in the event of the combination of "high differential pressure and high temperatures" ** drinking water approvals: KTW, DVGW-Arbeitsblatt, W 270, WRAS, BELAQUA  Please consult us • If you require combinations with high differential pressure and high temperatures – (see * in  Table "Material description").
  • Page 12: Name Plate

    Specifications Name plate The name plate (1) contains the following details: • Vogelsang address • CE marking • Pump type • Serial number • Year of construction Fig. 1: Name plate WBV.PU.004.EN V3.2...
  • Page 13: Safety

    Failure to comply with the instructions and safety information specified in this manual may result in serious hazards. In the event of any abnormalities and/or signs relating to the safety of the product supplied by Vogelsang, please contact us without delay via: produktsicherheit@vogelsang-gmbh.com...
  • Page 14: Personnel Qualification

    Safety devices may only be connected and checked by qualified technical personnel. • Electrical work and work on the electrical system may only be performed by qualified electricians. Vogelsang must always be consulted prior to any system-specific activities that are not described in this  manual.
  • Page 15: Intended Use

    The pumps described in these operating instructions are not intended for use in potentially explosive atmospheres. Any other use is contrary to the intended use. Vogelsang is not liable for any damage resulting from such incorrect use. General safety notes...
  • Page 16: Safety Devices

    Safety CAUTION Risk of burning due to exposed host surfaces! If the medium temperature is greater than 60 °C or the pump experiences dry running, the pump housing, the connectors or the pipes can become very hot. At high speeds or high differential pressure, the gearbox housing can also become very hot. •...
  • Page 17: Warning And Safety Stickers On The Machine

    Safety Warning and safety stickers on the machine Warning and safety stickers on the machine • provide important information for the safe operation of the machine. Observing the stickers is for the safety of persons who work with and on the machine. •...
  • Page 18: Transport, Storage

    Transport, storage Transport, storage Transport Fig. 3: Transport aids WARNING Risk of crushing or concussion due to falling machine! The machine may start to sway or topple when it is transported, loaded or set down. To ensure safe transport, note the following: •...
  • Page 19: Storage

    Transport, storage Storage Complete pumps, cartridge mechanical seals, individual O-rings and seal components If not stored and handled properly, the physical characteristics of products made of rubber may change. Possible consequences include excessive hardening, softening, permanent deformation, peeling, cracking or other surface damage.
  • Page 20: Assembly

    Assembl y Assembly Installation in pipes • The pump may be installed either upright or at 45°. If it is installed at 45°, the buffer chamber and gear box drain holes should face downwards. • When installing the pump, ensure that there is easy access for maintenance work. If the screw plugs for draining the gear oil and buffer fluid are not easy to access, discharge hoses may be used (part no.
  • Page 21: Pipes

    Assembl y Pipes • Only use the pipe diameters, wall thicknesses and materials recommended by us or by our representatives. The sealing material must be compatible with the medium. • Position the pressure and suction connections pointing upwards. This will ensure that the fluid remains in the pump after it is switched off.
  • Page 22: Fig. 5: Long Suction Lines

    Assembl y ATTENTION To protect from high pressure losses and cavitation, heed the advice for laying the suction lines: • The maximum suction height is 8 m. This is the maximum distance between the lowest and highest points of the suction pipe. Observe NPSH. •...
  • Page 23: Direction Of Flow

    Assembl y Direction of flow The pump is suited for both flow directions. Please observe the machine and safety technology exceptions in which the flow direction is predefined  Chapter "Pump units". 6.3.1 Pump with motor drive If you are using motor-driven pumps with one drive shaft, the flow direction is selected by determining the direction of rotation of the drive motor, such as an electric motor or hydraulic motor.
  • Page 24: Pump Connection

    Assembl y Pump connection ATTENTION Risk of breakage due to connectors under tension! Flange connections can exert excessive forces on the machine. The connectors must be mounted stressless. In other words, the connectors have to be precisely one in front of the other, even when they are not screwed into place.
  • Page 25: Base, Support Surface For Machine

    Assembl y Base, support surface for machine 6.5.1 Machine without base WARNING Risk of crushing or concussion due to falling machine caused by insufficient stability! • The machine must be securely fastened to the supporting surface. The machine must never be held in position by the connected pipe as this could result in the couplings breaking or failing.
  • Page 26: Coupling Orientation

    ATTENTION Vibration and wear due to incorrectly oriented coupling! If completely assembled at the Vogelsang plant, the alignment between the machine and the motor has been optimally adjusted. In the case of a drive provided by the operator, the tolerance specifications of the manufacturer of the coupling must be complied with.
  • Page 27: Machine And Motor On Base B (Belt Drive)

    Assembl y Coupling guard WARNING Injuries caused by friction, catching, abrasion from the exposed rotating coupling! During start-up and operation of the machine, the rotating coupling may be touched accidentally. • The coupling must be completely covered by a coupling guard. •...
  • Page 28: Drive

    Assembl y Drive The technical specifications for the drive system to be installed are determined by the machine's specifications  Chapter "Specifications". In addition, also read and note the following: "Technical information for the drive system to be installed". WARNING Injuries caused by friction, catching, grazing from the exposed rotating drive shaft/coupling! If the machine starts up unexpectedly during assembly or repair work, this can result in accidental contact with the exposed rotating drive shaft/coupling.
  • Page 29: Electric Drive

    Assembl y 6.6.1 Electric drive Connection to the energy supply may only be established by qualified technical personnel following installation in the pipe. RISK OF ELECTRIC SHOCK Touching live parts leads to dangerous electrocution. This can result in electric shock, burns or death. RISK OF ELECTRIC SHOCK The equipotential bonding shall be executed in accordance with standard EN 60204-1.
  • Page 30: Hydraulic Drive

    • Connect the overflow oil line in accordance with the manufacturer's instructions. • Replace hydraulic hose lines that show signs of damage or ageing. Only use genuine Vogelsang hydraulic hose lines. • The date of manufacture of the hydraulic hose line is displayed on the pressing component of the connector.
  • Page 31: Combustion Engine Drive

    Assembl y 6.6.3 Combustion engine drive In addition, also read and note the following: "Technical information for combustion engine" Before start-up • Fill the tank with fuel. The fuel must meet the specifications in the operating instructions. • Fill up with sufficient operating oils. The oil grade must meet the specifications in the operating instructions.
  • Page 32: System Control

    Assembl y System control Controls We recommend our control system, which is specially designed for use with the pump in order to provide optimum service life for the pump . All connections necessary for connecting the pump to a control system are available.
  • Page 33: Start-Up

    Start-up Start-up Personnel for start-up and operation We recommend starting up the machine in the presence of persons who are responsible for further operation of the machine. WARNING Risk of injury, catching by rotating rotary lobes! The pump may only start-up if the inlet and outlet pipes are connected so that access to the rotating rotary lobes in the pumping chamber is not possible.
  • Page 34 Start-up Check list before start-up Pump connector  Are the inlet and outlet lines connected?  Are the drain cocks closed, and is the pump filled with fluid? Base, coupling  Is the coupling, if present, correctly oriented (see documents provided by the coupling manufacturer)? Drive ...
  • Page 35: Maintenance

    Maintenance Maintenance WARNING Risk of injury (catching, crushing, collision) due to rotating rotary lobes if the machine starts up unexpectedly! Before starting maintenance and repair work (opening covers, disassembling connectors) and before troubleshooting, switch the machine off and secure it against being switched on again. WARNING Risk of injury from working materials escaping under high pressure! When the drain plugs on the gearbox and buffer chamber are loosened or the buffer fluid tank cover is...
  • Page 36: Pressurisable Buffer Fluid Tank

    Maintenance 8.1.1 Pressurisable buffer fluid tank The pressurisable buffer fluid tank (hereafter referred to as "tank") with manual air pump ensures a constant and defined buffer chamber pressure (buffer chamber pressure = tank pressure). The tank provides reliable monitoring of the buffer chamber. Installing the tank (before pump start-up) Remove the plug from the buffer chamber.
  • Page 37: Fig. 12: Filling/Draining The Buffer Chamber

    Maintenance Upright installation 45° installation Fig. 12: Filling/draining the buffer chamber Screw plug Filling Buffer fluid tank Draining WBV.PU.004.EN V3.2...
  • Page 38 Maintenance Tank pressure The tank pressure should be about 0.5 bar higher than the average pressure in the pump. Tank pressure = 0.5 bar + (pressure on the suction side + pressure on the discharge side) / 2 Example A pump primes with 0.4 bar suction and discharges with 2.0 bar overpressure. Pressure on the suction side: –0.4 bar, pressure on the discharge side: 2.0 bar.
  • Page 39: Buffer Fluid - Type

    Maintenance Buffer fluid – type 8.1.2 For optimum functioning of the mechanical seal, we recommend the oil grades listed in  Chapter "Oils". Please check your order confirmation to see whether the buffer chamber of your machine is filled with an oil that deviates from this chapter.
  • Page 40: Draining And Cleaning The Buffer Chamber

    Maintenance Draining and cleaning the buffer chamber Draining and cleaning the buffer chamber • If the cartridge mechanical seal is defective, drain and clean the buffer chamber. • Before changing a cartridge mechanical seal, drain the buffer chamber, and clean it if it is contaminated severely.
  • Page 41: Dry Buffer Chamber" Sealing System

    Maintenance "Dry buffer chamber" sealing system This sealing system is only used if it is essential to prevent buffer chamber fluid from getting into the pump medium. It is used for pumps that pump pure, non-abrasive media, e.g. water. To prevent contamination of the pump medium, no fluid must be filled into the buffer chamber of pumps with the "dry buffer chamber"...
  • Page 42: Gearbox

    Maintenance Gearbox 8.4.1 Gear oil - grade We recommend the oils listed in  Chapter "Oils". 8.4.2 Gear oil - quantity 1.4 litre Gearbox oil – inspection and change 8.4.3  Fig. "Gearbox oil change" Check the gearbox oil and top up small quantities up to the seal indicator pipe (C) (only top up when the gearbox is at a standstill): ...
  • Page 43: Oils

    Maintenance Oils Standard Vogelsang oil for pump gearboxes and buffer chamber Part number BSS.006 Description EP (Extreme Pressure) gear oil Trade name (Fuchs) Titan Gear MP 90 Characteristics Test acc. to SAE class 90 (85W-90) DIN 51512 or SAE J306c...
  • Page 44 Maintenance Alternative oils for pump gearboxes and buffer chamber Part number BSS0021* Description Fully synthetic industrial gear oil based on poly-alpha- olefins Trade name (Fuchs) Renolin Unisyn CLP Characteristics Test acc. to ISO VG DIN 51519 Kinematic viscosity DIN EN ISO 3104 at 40 °C 220 mm²/s at 100 °C...
  • Page 45 Maintenance Alternative oils for the buffer chamber Part number BSS.014 Description Mineral oil based hydraulic and lubricating oil Trade name (Fuchs) Renolin B 15 Characteristics Test acc. to ISO VG DIN 51519 Viscosity index DIN ISO 2909 Kinematic viscosity DIN EN ISO 3104 at 40 °C 46 mm²/s at 100 °C...
  • Page 46 Maintenance Oils for the buffer chamber with electronic buffer chamber monitoring Part number BSS.021 Description Fully synthetic EP industrial gear oil based on selected polyglycols (PAG) Trade name (Fuchs) Renolin PG 100 Characteristics Test acc. to ISO VG DIN 51519 Kinematic viscosity DIN EN ISO 3104 at 40 °C...
  • Page 47: Repair

    Conversion and spare parts Modifications or changes to the machine are only permissible after consultation with Vogelsang. Only accessory parts approved by Vogelsang or genuine spare parts may be used. The use of other parts invalidates the guarantee for any resulting damage.
  • Page 48: Opening The Iq Cover

    Repair Opening the IQ cover Depressurise the entire pump unit. Shut off the connected pipes if possible. Drain the pump as much as possible. Attention! Any remaining fluid will flow out of the machine when the Q cover is dismounted. Depressurise the buffer chamber if necessary ...
  • Page 49: Rotary Lobe Change

    Repair Rotary lobe change Lobe puller for pump size 81, 114 PBA.D001.TL.N1 ATTENTION Risk of premature wear on rotary lobes made of FPM in the event of excess pump pressure! The material 'FPM' for rotary lobes is usable only up to max. 6 bar differential pressure. Please see ...
  • Page 50: Fig. 16: Rotary Lobe Change

    Repair Fig. 16: Rotary lobe change Position of pressure disc and spring washer Correct position: Attention! Incorrect assembly: Fig. 1: Position of pressure disc and spring washer Pressure disc Spring washer WBV.PU.004.EN V3.2...
  • Page 51: Change Of Wear Plates

    Repair Change of wear plates ATTENTION The wear plates have a defined curvature. To prevent premature wear by the rotary lobes, the correct installation position of the wear plate must be observed during installation  Fig. "Installation position of the curved wear plates".
  • Page 52: Change Of Cartridge Mechanical Seal

    Repair Change of cartridge mechanical seal Cartridge mechanical seal – installation/disassembly tool: Part no. WKZ0455  Fig. “Cartridge mechanical seal on the gearbox” Depressurise the buffer chamber if necessary  Chap. “Buffer chamber”. Drain and clean the buffer chamber. Drain gear oil. If available, dismount locking screws.
  • Page 53: Fig. 18: Cartridge Mechanical Seal On The Gearbox

    Repair Fig. 18: Cartridge mechanical seal on the gearbox Set screw O-ring (seal carrier) Cylinder head bolt* Installation/disassembly tool* Hexagon head bolt* * included in tool with part no. WKZ0455 WBV.PU.004.EN V3.2...
  • Page 54: Closing The Iq Cover

    Repair Closing the IQ cover Fig. "Opening/closing the IQ cover" Thoroughly clean the contact surfaces before installing the IQ cover (5). Place the O-ring (6) in the four flat O-ring grooves (13). Put the IQ cover in place, orient it on the spring pins (12) and secure it. Screw in eight hexagon head bolts and tighten them uniformly.
  • Page 55: Troubleshooting

    Troubleshooting 10 Troubleshooting 10.1 Troubleshooting Help  Chapter "Help" Troubleshooting • No pump delivery A, B, D, E, G, J, R • Pump stops after start J, K, M, R, S, V • Intake flow breaks away after start D, E, G, S, V •...
  • Page 56 Material description for Medium temperature below Increase medium temperature (after consulting rotary lobes the nominal value Vogelsang). Pressurise the buffer chamber once with the max. permissible buffer chamber pressure (tank pressure) (single mechanical seal: 5 bar, double mechanical seal: 10 bar).
  • Page 57: Putting Out Of Operation And Disposal

    Putting out of operation and disposal 11 Putting out of operation and disposal Disconnect pump from the power supply. Observe notices and safety instructions  Chapter "Drive". Disconnect pump from the pipe. Observe notices and safety instructions  Chapter "Installation in pipes".
  • Page 58 Maintenance and service plan WBV.PU.004.EN V3.2...
  • Page 59: Maintenance Plan

    Maintenance plan 12 Maintenance plan 12.1 Maintenance instructions ATTENTION! Carefully follow the following maintenance instructions and, if applicable, document them in the service plan  Chap. “Service plan”. Safety devices must be checked on a regular basis for proper function, especially after maintenance and repair work and before start-up.
  • Page 60: 12.3 Additional Maintenance Intervals For Pumps With Belt Drive

    Maintenance plan 12.3 Additional maintenance intervals for pumps with belt drive See also “Technical information for belt drives TINF.PU.020.xx”. Before start-up and after long periods of shutdown: Check belt tension and belt orientation After 0.5 to 4 operating hours: Check belt tension Every 6 months: •...
  • Page 61: Service Plan

    Service plan 13 Service plan The guarantee is valid only if maintenance and service work is performed and documented acc. to  Chap. “Maintenance plan”. Serial number: _________________________ Activity as per maintenance plan Operating hour meter/ Date Signature Total capacity WBV.PU.004.EN V3.2...
  • Page 62 S.de R.L. de CV vogelsang-czech.cz vogelsang.mx Finnland Österreich Vogelsang Oy Vogelsang Austria GmbH Vogelsang USA Ltd. vogelsang.fi vogelsang-austria.at vogelsangusa.com Frankreich Polen Vogelsang France S.A.R.L. Vogelsang Poland Sp. z o.o. vogelsang.fr vogelsang.pl Großbritannien Rumänien Vogelsang Ltd. Vogelsang Romania SRL vogelsang.co.uk vogelsang.ro WBV.PU.004.EN V3.2...

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