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Alfa level 3S Series Instruction Manual

Three-screw pumps with magnetic coupling
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Instruction Manual
Alfa Laval Three-Screw Pumps with Magnetic Coupling - 3S Series
ESE02461-EN1
Original manual
2013-05

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  • Page 1 Instruction Manual Alfa Laval Three-Screw Pumps with Magnetic Coupling - 3S Series ESE02461-EN1 2013-05 Original manual...

  • Page 3: Table Of Contents

    Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice 1. EC Declaration of conformity ............... 2. Safety ....................2.1. Generel information ................2.2. Target groups ..................2.3. Symbols ...................
  • Page 4 Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice 7. Spare parts ..................... 7.1. Maintenance sets ................. 7.2. Repair sets ..................7.3. Completions ..................

  • Page 5: Ec Declaration Of Conformity

    1 EC Declaration of conformity The designated company Alfa Laval Company Name Albuen 31, DK-6000 Kolding, Denmark Address +45 79 32 22 00 Phone No. hereby declare that Three-Screw Pump 2013-05-01 Denomination Type Year Is in conformity with - Machinery Directive 2006/42/EC and futhermore declares that if motorised the following applicable directives have been used - Directive 2006/95/EC on low voltage - EMC Directive 2004/108/EC...

  • Page 6: Safety

    2 Safety 2.1 Generel information The operating instructions form part of the pump/pump unit and must be kept for future reference. Furthermore please observe the associated documents. 2.2 Target groups Target groups Tasks Operator - owner - Keep these instructions available at the system site for future reference. - Ensure that employees read and observe these instructions and the associated documents, in particular the safety instructions and warnings.

  • Page 7: Proper Use

    2 Safety 2.5 Proper use - Use the pump solely for transporting lubricating liquids that are chemically neutral and that contain no gas or solid components. - Use the pump only within the operating limits specified on the name plate and in the Chapter "Technical data". In the case of operating data that does not agree with the specifications on the name plate, please contact the manufacturer.

  • Page 8: Installation

    3 Installation 3.1 Unpacking and checking the state of delivery 1. On delivery unpack the pump/pump unit and check for damage during transportation. 2. Report damage during transportation immediately to the manufacturer. 3. Dispose of packing material in accordance with the locally applicable regulations. 3.2 Lifting the pump/pump unit Fig.

  • Page 9: Storage

    3 Installation DANGER Risk of injury and/or damage to equipment should the pump/pump unit fall. Use intact and correctly dimensioned hoisting equipment. Attach the hoisting equipment correspondingly. Secure motors additionally against tilting. Do not stand under raised loads. Pump 1. Screw eye bolts into two opposing holes at the flange cover, see Fig. 1, page 8. 2.
  • Page 10 3 Installation Preserving the internal surfaces of the pump 1. Close the suction connection of the pump with a blind flange. 2. Pour non-corrosive, resin-free oil into the pressure connection until it reaches approx. 2 cm under the pressure flange, while slowly turning the main screw against the direction of rotation.

  • Page 11: Disposing Of The Pump

    3 Installation 3.5 Disposing of the pump Aids: - Solvents or industrial cleaners suitable for the pumped liquid. WARNING Danger of poisoning and environmental damage from the pumped liquid. Wear protective clothing during all the work. Before disposing collect the discharging pumped liquid and dispose of in accordance with the locally applicable regulations.

  • Page 12: Installation

    3 Installation 3.6 Installation Observe the following instructions: - When selecting the location take the operating limits, NPSH values and ambient conditions into account, see "Technical data". - The function, safety and service life may not be impaired by humidity, temperature influences or explosive atmospheres. - During the installation ensure that all the parts can be accessed easily and that the maintenance work can be carried out easily.

  • Page 13: Connecting The Motor

    3 Installation Connecting the pump to the pipe system CAUTION Danger of damage to the device or impaired functionality through mechanical stresses. Ensure that the pump mounting on the pipe system is free of mechanical stress. 1. Turn the pump shaft or fan impeller of the motor so that smooth running of the pump is checked. If the pump cannot be turned by hand, remedy the fault before installing the pump, see "Troubleshooting".

  • Page 14: Heating System

    3 Installation DANGER Risk of death resulting from electric shock. Ensure that the power supply is de-energized. The motor may only be separated from the power supply by anauthorized electrician. WARNING Risk of injury through emitted hot, poisonous or corrosive pumped liquid. Wear protective clothing during all the work.
  • Page 15 3 Installation The electric heating system consists of one or two heating elements 2 that are integratedin a heating cover 1 attached additionally to the end cover. The output of the cartridges corresponds to the radiation and convection losses of the pump in the required temperature range so that overheating is not possible.

  • Page 16: Fluid Heating System

    3 Installation DANGER Risk of death resulting from electric shock. The electric heating system may only be connected by anauthorized electrician. Ensure that the power supply is de-energized during the connecting work. WARNING Danger of the pump housing bursting and danger of injury through emitted pumped liquid through the heat expansion of the pumped liquid.

  • Page 17: Heating System Special Design

    3 Installation 1. Remove the socket screws and rating plate at the end cover of the pump. 2. Mount the heating cover to the end cover using the supplied socket screws. 3. Mount the piping. 4. Mount the rating plate on the heating cover. Commissioning the fluid heating system Required heating-up period for the temperature difference of 50°C at a liquid temperature of 200°C: Heating-up period [min] at a temperature difference of 50°C...

  • Page 18: Operation

    4 Operation 4.1 Commissioning The following safety instruction must be observed during commissioning: There is a risk of death for people with pacemakers. Under no circumstances may persons with pacemakers perform commissioning work. Be sure to observe the following instructions: The pump may only be commissioned by authorized qualified personnel.
  • Page 19 4 Operation Filling the pump via the suction or pressure connection WARNING Danger of injury or poisening through dangerous pumped liquids. Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible manner 1. Open the vent hole 1 so that the air can escape during the filling process. 2.
  • Page 20 4 Operation 1. Rotation-direction arrow 2. Arrow for flow direction Fig. 2 Identifying direction of rotation and flow direction CAUTION Dry running can damage pump equipment Ensure that the pump is filled properly. Switch the pump on for a maximum of 1 second and then off again immediately. 1.

  • Page 21: During Operation

    4 Operation 1. Switch on the pump. The pump will deliver when the pressure on the pressure side of the pump rises or a system-side flow indicator triggers. 2. If the pump does not deliver after 10–15 seconds of operation, abort commissioning, establish the cause of the fault and only then continue the commissioning procedure.

  • Page 22: Taking The Pump Out Of Operation

    4 Operation WARNING Risk of injury or poisoning through emitted pumped liquid Wear protective clothing during all the work. Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible manner. 1. Switch on the pump and open the screw plug 1 of the overflow valve. 2.

  • Page 23: Recommissioning The Pump

    4 Operation Behavior of the pumped Duration of the operation interruption liquid Long Short - Sediment solids Rinse the pump. Rinse the pump. - Congealed/frozen Heat or drain the pump. Drain the pump. - No corrosive burden - Congealed/frozen Heat or drain the pump. Drain the pump.

  • Page 24: Maintenance

    5 Maintenance 5.1 Safety instructions Safety instructions on maintenance and repairs The following safety instructions must be observed during all the repair work: There is a risk of death for people with pacemakers. Under no circumstances may persons with pacemakers perform maintenance or repair work. All the work may only be carried out by authorized qualified personnel.

  • Page 25: Replacing The Magnetic Coupling

    5 Maintenance 5.3 Replacing the magnetic coupling Removing the magnetic coupling Dismantling the outer rotor Fig. 1 Fig. 2 052 Coupling hub 180 Pump bracket 515 Outer rotor 884* Threaded pin 914.4 Socket screws 917** Countersunk screw ** Depending on motor size Fig.
  • Page 26 5 Maintenance Dismantling the inner rotor Fig. 5 Fig. 6 Fig. 7 Containment can Inner rotor 914.3 Socket screw Pump bracket Tensioning element 914.5 Socket screw Aids: - Anti-rotation screw - Allen key 1. Loosen the socket screws 914.3 between the pump and pump bracket 180 and remove the pump bracket, see Fig. 5. 2.

  • Page 27: Installing The Magnetic Coupling

    5 Maintenance 5.4 Installing the magnetic coupling Mounting the inner rotor Fig. 8 Fig. 9 Fig. 10 038 Contaiment can 040 Distance sleeve 180 Pump bracket 518 Inner rotor 585 Tensioning element 739 O-ring 914.3 Socket screw 914.5 Socket screw Fig.
  • Page 28 5 Maintenance Mounting the outer rotor Fig. 13 Fig. 14 Fig. 15 052 Coupling hub 180 Pump bracket 515 Outer rotor 884** Threaded pin 914.4 Socket screw 917* Countersunk screw 1 Motor ** Depending on motor size Fig. 16 Fig. 17 1.

  • Page 29: Replacing The Ball Bearing And Screw Set

    5 Maintenance 5.5 Replacing the ball bearing and screw set Removing the ball bearing and screw set Fig. 18 Fig. 19 Fig. 20 Fig. 21 Fig. 22 Fig. 23 056 Supporting ring 661.1 Main screw 817 Ball bearing 471.2 Circlip 661.2 Idle screw 1 Flange cover 1.
  • Page 30 5 Maintenance Installing the ball bearing and screw set Fig. 24 Fig. 25 Fig. 26 Fig. 27 Fig. 28 Fig. 29 056 Supporting ring 729.5 Flat gasket 471.2 Circlip 817 Ball bearing 471.3 Circlip 1 Flange cover 661.1 Main screw 2 Mounting sleeve ball bearing 661.2 Idle screw Fig.

  • Page 31: Possible Faults

    5 Maintenance 5.6 Possible faults Faults can have different causes. The following tables list the symptoms of a fault, the possible causes and measures for elimination. Fault Cause/Remedy - No pump suction 1, 2, 3, 4, 5, 6, 7, 8, 28 - Delivery rate too low 2, 3, 4, 9, 10, 11, 12, 13, 14, 15, 16, 17 - Pump runs noisily...
  • Page 32 5 Maintenance No. Cause Remedy Airlock or gas in the liquid Test the pipe system for air admission and replace parts if necessary. Reduce the suction head - or - Increase the inlet pressure. Motor running at wrong voltage or Ensure that the motor voltage and frequency match the operating frequency voltage.

  • Page 33: Technical Data

    6 Technical data 6.1 Type code Fig. 1 Type code Item Designation Type Model Pump with free shaft end 3SBI Pump housing with flanges PN16 in inline configuration Pump unit with or without pump bracket foot Pump with free shaft end 3SBS Pump housing with overhead special flanges PN16 Pump unit with or without pump bracket foot...

  • Page 34: Name Plate

    6 Technical data 6.2 Name plate Manufacturer Al f a Laval , Al b uen 31, Kol d i n g, DK-6000 Pump Type Serial No. Year Item No. Service enquiries www.alfalaval.com Produced by Kral AG 3012-0068 Fig.2 Name plate 6.3 Operating limits Size 55 -...

  • Page 35: Required Npsh Values

    6 Technical data 6.5 Required NPSH values The following table lists the required NPSH values during operation with a low-volatile liquid such as lubricating oil or hydraulic liquid. When liquids have a readily volatile component content, there quired NPSH values increase notably: - Fuel oil requires an NPSH value of at least 6 mWC.

  • Page 36: Weights

    6 Technical data 6.6 Weights Model 3SBI/3SBS/3SBT Motor Motor Magnet Size 1500 2200 size weight power 1700 2500 [kg] [Nm] 1101 2900 1301 Weight of pump with free shaft end [kg] 10.5 21.5 21.5 36.5 85.5 Weight of pump bracket with pump bracket foot, magnetic coupling and screws [kg] 100L 16.9 10.3...
  • Page 37 6 Technical data Model 3SVI/3SVT Motor Motor Magnet Size 1500 2200 size weight power 1700 2500 [kg] [Nm] 1101 2900 1301 Weight of pump with free shaft end [kg] 10.5 21.5 21.5 36.5 85.5 Weight of the pedestal [kg] 17.8 27.1 62.2 70.0...
  • Page 38 6 Technical data Motor Motor Magnet Size 1500 2200 size weight power 1700 2500 [kg] [Nm] 1101 2900 1301 160L 11.1 11.1 24.8 24.8 18.6 19.4 18.1 20.0 20.0 18.8 19.6 19.6 11.2 11.7 11.7 13.4 16.4 25.5 38.9 13.8 40.5 180M 18.9...

  • Page 39: Structure

    6 Technical data 6.7 Structure Fig. 3 Structure of 3S-pump 1. Screw plug 7. Flange cover 2. Overflow valve 8. Vent hole 3. Pump housing 9. Thrust pin 4. Balancing cylinder 10. End cover 5. Ball bearing 11. Idle screw 6.

  • Page 40: Housing Variants

    6 Technical data Screw pumps are rotating displacement pumps whose displacement effect results from the meshing of three rotating screws and the enclosing housing. The radial support of the screws is effected by the sliding contact in the housing which requires lubrication by the pumped liquid.

  • Page 41: Magnetic Coupling

    6 Technical data 6.9 Magnetic coupling Magnetic coupling The shaft end of pump K1 is enclosed by a containment can K2, that is connected air-tight with the motor-side flange of the pump. Therefore, it is not necessary to seal a rotating free shaft end against a stationary seal housing. Special rotors equipped with powerful permanent magnets are used for transfer of torque from the motor to the pump.

  • Page 42: Tightening Torques

    6 Technical data 6.11 Tightening torques Tightening torque [Nm] for screws with metric threads + head contact surfaces with thread measured in inches + wedge lock Stainless steel Screw plugs with elastomer washers screws seal A2 and A4 Thread 10.9 8.8 + Rust- Property...

  • Page 43: Spare Parts

    7 Spare parts 7.1 Maintenance sets NOTE The maintenance sets contain only the numbered parts and are only supplied complete. Mechanical coupling 3SBI/3SVI 5-660 Qty. Pos. no. Part Qty. Pos. no. Part Supporting ring Flat gasket 055* 729.5 Supporting ring Flat gasket, suction flange 729.6 Screw plug...
  • Page 44 7 Spare parts Mechanical coupling 3SBI/3SVI 851 - 1301 Pos. no. Part Qty. Pos. no. Part Qty. Supporting ring Flat gasket, suction flange 729.6 Flat gasket, pressure flange Supporting ring 729.7 165.1 Screw plug O-ring 165.2 Screw plug Ball bearing Screw plug 165.3 914.1...
  • Page 45 7 Spare parts Magnetic coupling 3SBI/3SVI 1500 - 1700 Pos. no. Part Qty. Pos. no. Part Qty. Supporting ring Flat gasket, suction flange 729.6 Supporting ring 729.7 Flat gasket, pressure flange 165.1 Screw plug O-ring Ball bearing 165.2 Screw plug Screw plug 165.3 914.1...
  • Page 46 7 Spare parts Magnetic coupling 3SBI/3SVI 2200 - 2900 Qty. Pos. no. Part Qty. Pos. no. Part Supporting ring 729.5 Flat gasket, pressure flange Threaded ring 729.6 O-ring Screw plug Ball bearing 165.1 Screw plug 165.2 914.1 Socket screw Screw plug 165.3 914.2 Socket screw...
  • Page 47 7 Spare parts Magnetic coupling 3SBT Pos. no. Part Qty. Pos. no. Part Qty. Balancing cylinder Flat gasket 729.4 Supporting ring Flat gasket 055* 729.5 Supporting ring Flat gasket, suction flange 729.6 Flat gasket, pressure flange 165.1 Screw plug 729.7 165.2 Screw plug O-ring...

  • Page 48: Repair Sets

    7 Spare parts 7.2 Repair sets NOTE The repair sets contain only the numbered parts and are only supplied complete. Overflow valve 3SBI/3SVI 5 – 660 Qty. Pos. no. Part Qty. Pos. no. Part Adjusting screw Spring 165.1 Screw plug 729.4 Flat gasket Valve body...
  • Page 49 7 Spare parts Overflow valve 3SBI/3SVI 851 – 1301 Qty. Pos. no. Part Qty. Pos. no. Part Supporting ring Valve housing Adjusting screw Flat gasket 729.4 Screw plug 165.1 914.2 Socket screw Valve body 914.5 Socket screw Groove nut 914.6* Socket screw Spring Only for 3SVI: replaces 4 pieces 914.2...
  • Page 50 7 Spare parts Overflow valve 3SBI/3SVI 1500 – 1700 Qty. Pos. no. Part Qty. Pos. no. Part Supporting ring Valve housing Adjusting screw Flat gasket 729.4 Screw plug 165.1 914.2 Socket screw Valve body 914.5 Socket screw Groove nut 914.6* Socket screw Spring Only for 3SVI: replaces 4 pieces 914.2...
  • Page 51 7 Spare parts Overflow valve 3SBI/3SVI 2200 – 2900 Qty. Pos. no. Part Qty. Pos. no. Part Spring Sleeve Valve housing Supporting ring Adjusting screw Flat gasket 729.4 Screw plug 165.1 914.2 Socket screw Valve body 914.5 Socket screw Groove nut 914.6* Socket screw Only for 3SVI: replaces 4 pieces 914.2...
  • Page 52 7 Spare parts Screw set NOTE The repair set, screw set is only supplied in combination with a maintenance set. Qty. Pos. no. Part Qty. Pos. no. Part Balancing cylinder Screw set Circlip 471.1 Magnetic coupling 3SBI/3SVI Qty. Pos. no. Part Qty.

  • Page 53: Completions

    7 Spare parts 7.3 Completions Model 3SBI Pos. no. Part Pos. no. Part Pump bracket 914.3 Socket screw Pump bracket foot 914.6 Socket screw Hexagon nut 914.7 Socket screw...
  • Page 54 7 Spare parts Model 3SVI Pos. no. Part Pos. no. Part Pump bracket 914.6 Socket screw Pedestal 914.9 Socket screw 914.3 Socket screw...
  • Page 56 How to contact Alfa Laval Contact details for all countries are continually updated on our website. Please visit www.alfalaval.com to access the information directly. © Alfa Laval Corporate AB This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is the responsibility of the user of this document to comply with all applicable intellectual property laws.

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