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Related Manuals for VERDER PACKO ZL Series
Summary of Contents for VERDER PACKO ZL Series
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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 Adjustment Pressure Relief Valve 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 ZL series Rotary Lobe 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: (TL-120) D37SSVQ TL: Lobe type (TL = tri-lobe, BW = bi-wing, HL = heli-lobe) 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: Construction
1.8 CONSTRUCTION ZL series Rotary Lobe Pumps can be ordered with bare shaft, i.e. pumps without motor or base plate. Or, ordered as a complete unit with drive motor, coupling & guard, base plate (or trolley) and layout described as below. Example Layout of pumps with complete unit ①... -
Page 8: Packaging & Transport
1.9 PACKAGING & TRANSPORT ZL 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 transporting 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) Non 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 (Due to the pressure limitation, the ZL440 - ZL450 has only one spring type up to 10 bar, here are other options.) How it works: The spring marked in red exerts pressure on the pump cover. The further this spring is compressed with the hex screw, which is also marked in red, the higher the pressure on the pump casing cover.
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Page 13: Connection Of The Motor
Distance in mm 3.3 CONNECTION OF THE MOTOR The electrical connections may only be made when no electrical power is connected and by qualified personnel in accordance with EN 60204 and the local regulations. Special attention must be paid to optimal earthing of the motor; this must be performed in accordance with the applicable regulations in the relevant country. -
Page 14: Connecting The Mechanical Seal Flush
Inspect the seal of the gland. The gland must match the diameter of the connecting cable used. Bending of the cable beside the gland must not allow water to penetrate. (Allow the cable to be routed downwards when it leaves the motor.) Connect the motor in star or delta according to the designation on the name plate of the motor and in accordance with the diagram that is installed in the terminal box. - Page 15 6. The pump must never be driven against a closed discharge valve. Please make sure the pressure at the discharge does not exceed the maximum pressure as indicated on the nameplate of the pump. The installation of a pressure relieve valve is recommended. Pay attention to circumstances that could indicate pump cavitation: 1.
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Page 16: Check The Pump Rotation
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. It is then transported in the space between the lobes and the periphery of the rotor case to the discharge side. -
Page 17: 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 18: 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 19: 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 the product may be hardened, crystallized or frozen in the pump it should be thoroughly drained and cleaned immediately after use. -
Page 20: Inspection
After pulling out both rotors, the rotor case can be separated by sliding along the stud bolt and pulling out from the Gearbox. Inspect the rotor case for wear, clean and continue seal maintenance, if needed. Fig. 5 In this step, handle and place carefully to keep the right track of position of the top &... -
Page 21: 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 8), Double mechanical seal (Figure 9) and PTFE Triple lip seal (Figure 10). - Page 22 Single Mechanical Seal Maintenance Remove the Seal ring from the rotor case & rotor (shown in Figure 13) 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 fit into the seal pins on the seal body after Rotor Case Assembly (chapter 6.4).
- Page 23 Place the rotor case face down on the table and pull out carefully the Double seal body out of rotor case by hand shown in Figure 18. Lubricate the replacing double seal body or O-ring and insert it into the rotor case and fit into the Seal pin properly. See ‘Rotor Case Assembly’...
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Page 24: 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 and the Gearbox and make sure to put the shims between rotor case and Gearbox as originally. -
Page 25: Rotor Clearance
Use feeler gauges and a depth micrometer to verify the back and radial clearances between the rotors and the rotor case. A depth micrometer should be used to verify the front 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. -
Page 26: Rotor Timing
Front and back face clearance; adjustable by shim Rotor thickness and body depth are fixed at manufacturer. Therefore, with the correct rotor size selected, the only maintenance adjustment that can be made is the proportion of front and rear clearance. Measure the front clearance as follows: 1. - Page 27 5. Bend away the tab of the lock washer (12) on the drive shaft, loosen the lock nut and remove the gear. Insert a NEW gear spacer (6mm) on the drive shaft. Place the gear, lock nut and lock washer consequently and tighten referring the ‘Gearbox Assembly’...
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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. 35 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 36.
- 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.
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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 are required for particularly difficult operating conditions, such High temperature variations High pressure fluctuations The oil in the gearbox is recommended to be changed once a year or every 3,000 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/ZL100, ZL200 AND ZL300 EXPLODED VIEW / ZL100, ZL200 AND ZL300... - 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 views. SINGLE MECHANICAL SEAL & TRIPLE LIP SEAL Triple lip Seal DOUBLE MECHANICAL SEAL...
- Page 36 O-RING SEAL & DOUBLE O-RING SEAL FLUSHED MECHANICAL SEAL...
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Page 37: Exploded View Zl400
8.2 EXPLODED VIEW / ZL400... - Page 38 SINGLE MECHANICAL SEAL & TRIPLE LIP SEAL Single Mech. Seal Triple Lip Seal DOUBLE MECHANICAL SEAL...
- Page 39 O-RING SEAL & DOUBLE O-RING SEAL Double O-ring Seal O-ring Seal FLUSHED MECHANICAL SEAL...
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