1. Manuals
  2. Brands
  3. Borger Manuals
  4. Water Pump
  5. Classic FL Series
  6. Operating manual

Borger Classic FL Series Operating Manual

Rotary lobe pump
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Operating Manual
Börger Rotary Lobe Pump
Classic
FL Series
www.boerger.de
www.boerger.com

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Classic FL Series and is the answer not in the manual?

Questions and answers

JACOB ROCHA
February 15, 2025

Parts list for a FL 518

-1
1 comments:
Mr. Anderson
February 15, 2025

The parts list for the Börger Classic FL Series FL 518 includes:

- Parallel key dimensions:
- 14 x 9 x 82 mm
- 14 x 9 x 93 mm
- 14 x 9 x 207 mm

- Rotor options:
- Fusion rotors with integrated cover disk
- Rotors with separate cover disk (special version)

- Rotor types available:
- Tri-lobe, screw profile (Stainless steel rotor body, Type H, removable lobe tips)
- Optimum rotor (Dual-lobe, screw profile, Polymers, Type I, Steel/stainless steel)
- Premium rotor (Dual-lobe, linear, Polymers, Type J, Steel/stainless steel)
- Orbit rotor (Dual-lobe, linear, Type P)

- Timing gear:
- Synchronous drive through carrier shafts and gear wheels
- Shafts seated inside the carrier gear unit
- Gear unit separate from the pump chamber for maintenance ease
- Configurable with different drive shaft positions

This answer is automatically generated

0

Related Manuals for Borger Classic FL Series

Summary of Contents for Borger Classic FL Series

  • Page 1 Operating Manual Börger Rotary Lobe Pump Classic FL Series www.boerger.de www.boerger.com...
  • Page 2 France Börger France S.A.R.L. Phone +33 (0) 3 / 88515468 9 rue des Prés +33 (0) 3 / 88515413 67670 Wittersheim E-mail info@borger.fr France Internet www.borger.fr Great Britain/ Börger UK Ltd. Phone +44 (0) 1902 / 798977 Ireland East Wing - Old School +44 (0) 1902 / 798979 Watling St.
  • Page 3 Product Specifications Unit: Product group: Rotary lobe pump Type: FL 518, FL 776, FL 1036 Precise product specifications for your unit, with the exception of control units, can be found in the data sheet enclosed with this operating manual. Manufacturer’s address: Company: Börger GmbH Address:...

  • Page 4: Table Of Contents

    Table of Contents Table of Contents General information...................... 8 Introduction........................8 Notes on copyrights and property rights................8 Information for the operator..................... 9 Training and instruction....................10 Sample training topics....................11 Safety..........................13 General Information....................... 13 Notes on signs and symbols..................13 Proper use........................
  • Page 5 Table of Contents 3.1.8 Pipe connections on inlet and outlet................44 3.1.9 Units / drive options....................... 46 3.1.10 Options and accessories....................47 Operating principle......................48 Technical data........................ 49 3.3.1 Dimensions........................49 3.3.2 Performance data and maximum loads................. 52 Transportation, Storage and Installation..............55 Transportation........................
  • Page 6 Table of Contents 6.1.3 Cleaning the inside....................... 111 Maintenance and inspection..................114 6.2.1 Maintenance and inspection plan................114 6.2.2 Lubricant fill level and changing the lubricants............116 Repairs........................123 6.3.1 Notes on repair work....................123 6.3.2 Opening and closing the quick-release cover.............. 125 6.3.3 Rotors, removal and replacement................
  • Page 7 Table of Contents Parallel keys........................ 183 Checklist for commissioning..................183 EU Declaration of Conformity / EU Declaration of Incorporation......... 185 9.7.1 EU Declaration of Conformity..................185 9.7.2 EU Declaration of Incorporation.................. 186 Lubricant list........................ 187 9.8.1 Börger gear units......................188 9.8.2 Buffer fluid........................

  • Page 8: General Information

    General information General information Introduction This operating manual is an important aid for the correct and safe operation of the Börger machine. It contains important information for operating the Börger machine in a safe, proper and economical manner. Adhering to these instructions will help avoid associated dangers, reduce repair costs and downtimes and increase the reliability and service life of the Börger machine.

  • Page 9: Information For The Operator

    General information Information for the operator The operating manual is an integral part of the Börger machine. The operator is responsible for making the operating personnel aware of this manual. Additionally, the operator is obligated to ensure the notice and observance of national regulations for accident prevention and environmental protection, plus the notice and observance of super- vision and reporting duties taking special operational aspects into...

  • Page 10: Training And Instruction

    General information Training and instruction As the operator, you are obligated to inform and, if necessary, instruct your operating personnel in regard to the applicable legal and accident prevention regulations, as well as the available safety equipment on the Börger machine. This obligation also applies to all other safety equipment on and around the Börger machine.

  • Page 11: Sample Training Topics

    General information Sample training topics 1. Operational safety — Accident prevention regulations — General legal regulations — General safety instructions — Measures in the event of emergencies — Safety instructions for operating the Börger machine — Using the safety equipment on the Börger machine —...
  • Page 12 General information Confirmation of Training Training topic Date: Trainer: Trainer signature: Surname, first name Signature www.boerger.de / www.boerger.com BA-Classic FL_en-US, 03.05.2018...

  • Page 13: Safety

    Safety Safety General Information The Börger machine has been developed and constructed according to current state-of-the-art technology and recognized safety guidelines in observance of the valid safety regulations in the country of manufacture. However, operation of the Börger machine may endanger the operating person and cause damage to the Börger machine or other material assets in the following circumstances: —...
  • Page 14 Safety NOTICE! Indicates a possible hazardous situation or unsafe, dangerous work processes that may lead to damage to the machine or sur- rounding area. NOTE! Offers useful information on safe and proper operation. Arrow symbols describe work and/or operational steps. These steps must be carried out in the sequence of the numbering.
  • Page 15 Safety NOTE! Illustration of work steps: Some of the diagrams and photographic images used in this operating manual, which are only used to illustrate a function or a particular work step, show a different type of device, however the functional principle or work step is the same. BA-Classic FL_en-US, 03.05.2018 www.boerger.de / www.boerger.com...

  • Page 16: Proper Use

    Safety Proper use The rotary lobe pump is a self-priming, valveless positive displace- ment pump. The rotary lobe pump delivers the pumped medium specified in the data sheet continuously, at speed-proportional flow rates, in a gentle, low-pulsation procedure. NOTE! Proper use The rotary lobe pump or entire unit is configured exclusively for the operating conditions entered in your request/order and specified in the order confirmation and enclosed data...

  • Page 17: Residual Risk

    Safety Residual risk Even when all safety instructions are adhered to, there are residual risks involved in operating the Börger machine as detailed below. All persons that work on and with the Börger machine must be aware of these residual risks and observe the associated instruc- tions to avoid accidents or damage caused by these residual risks.
  • Page 18 Safety Moving parts DANGER! Risk of injury due to rotating parts! Moving parts can cause severe injury. — Do not reach into rotating parts or handle rotating parts when the machine is in operation. — Never open protective covers when in operation. —...
  • Page 19 Safety Spouting liquids WARNING! Risk of serious injuries caused by liquid spouting out or escaping gases! Gases or liquids may escape uncontrollably from seals and screw connections. Especially when flange connections are released and maintenance openings are opened, pressurized liquid can spout out at the cover.

  • Page 20: Qualifications For Operating Personnel

    Safety Qualifications for operating personnel WARNING! Personnel with insufficient qualifications represent a hazard! Insufficiently qualified personnel are not able to assess the risks when using the machine and expose themselves and others to the risk of serious or fatal injuries. —...
  • Page 21 Safety Mechanics Mechanics have completed professional training or are able to pro- vide evidence of having completed further training which enables them to perform the special tasks mentioned in these instructions on the system and its components. The skills acquired during training or further training enable mechanics to identify and evaluate hazards associated with the system and its components.
  • Page 22 Safety These include: — Knowledge about health and safety at work — Knowledge about the basics of first aid — Basics of electrical engineering — Construction, wiring and checking of circuits — Effects and dangers associated with electricity — Troubleshooting and documentation of the electrical system —...

  • Page 23: Personal Protective Equipment

    Safety Personal protective equipment Personal protective equipment serves to protect personnel from adverse effects to safety and health whilst working. Staff must wear personal protective equipment whilst carrying out various work on the plant. The individual sections of these instructions make specific reference to the requirements.

  • Page 24: Securing The Machine Against Restart

    Safety Securing the machine against restart WARNING! Risk of fatal injury if the plant is switched back on uncon- trolledly or without authorization! Switching the Börger machine on without authorization or uncon- trolledly can cause serious injuries. — Before switching back on, make sure that all safety devices are fitted and fully functional and that staff are not at any risk.

  • Page 25: Description Of The Safety Equipment

    Safety Description of the safety equipment WARNING! Risk of fatal injury if safety devices are not fully functional! Non-functional or overridden safety features may cause severe injuries, including death. — Check whether all safety features are functional and correctly installed before starting work with the machine. —...

  • Page 26: Coupling Guard

    Safety 2.8.2 Coupling guard The rotating shafts between the drive and functional unit are con- nected by a coupling, and must be secured by a fixed safety guard against reaching in and blockages caused by falling parts. Börger GmbH delivers units with couplings and drives including a screw-fixed coupling guard as standard.

  • Page 27: Markings And Signs

    Safety Markings and signs The symbols and information signs below are located in the work area. They refer to the immediate environment in which they are attached. WARNING! Danger due to illegible signage! Over time, stickers and signs can get soiled or become illegible due to other reasons, so that dangers are not recognized and necessary operating instructions cannot be observed.
  • Page 28 Safety Meaning: Nameplate according to Directive 2006/42/EC (Machinery Directive) and DIN EN 809 Location: In a clearly visible position on the machine Different address possible, e.g. when delivered through a subsidiary. CE marking not applicable for incomplete machines where only a declaration of incorporation may be delivered, and in certain other cases. Meaning: Grounding (bore hole for ground screw or terminal) Location:...

  • Page 29: Markings And Signs To Be Attached By The Operator

    Safety 2.10 Markings and signs to be attached by the operator The operator is obligated to label the pumped medium and the flow Ä Chapter 4.5.3 direction on the rotary lobe pump (see chapter “Checking the flow direction” on page 83). The operator may also be required to attach additional markings and signs on or around the Börger machine.

  • Page 30: Safety Instructions For Maintenance And Rectifying Malfunctions

    Safety Keep long hair tied and do not wear loose clothing or jewelry. There is always a danger of getting caught, pulled in or dragged along by moving components. If malfunctions occur on the Börger machine: Shut down the machine and downstream and upstream machines / system components.
  • Page 31 Safety Never stand under suspended loads. At the start of maintenance, repairs or machine care, clean any dirt or cleaning agents off the connections and screw connections. Do not use any aggressive cleaning agents. Use lint-free cleaning cloths. During installation, always tighten any screw connections that have been loosened for maintenance and repair work.
  • Page 32 Safety WARNING! Risk of fatal injury if the plant is switched back on uncon- trolledly or without authorization! Switching the Börger machine on without authorization or uncon- trolledly can cause serious injuries. — Before switching back on, make sure that all safety devices are fitted and fully functional and that staff are not at any risk.
  • Page 33 Safety NOTICE! Risk of severe material damage due to a delayed shut-down in the event of a malfunction! A delayed shut-down in the event of malfunction can cause per- manent damage to the Börger machine. — In the event of a malfunction, shut down the Börger machine and all upstream and downstream system components imme- diately until the cause has been rectified.
  • Page 34 Safety Maintenance and troubleshooting on the electrical system Personnel: Qualified electricians Protective equip- Occupational safety clothing, chemical ment: resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools for electrical work — The electrical system may only be opened, maintained and repaired by qualified electricians, while having proper regard to the attached electric circuit diagrams.
  • Page 35 Safety Protect the electronic components from moisture and impuri- ties. Clean the electronic components with suitable agents according to the manufacturers' operating manuals only. Do not use aggressive cleaning agents to clean the surface. Use lint-free cleaning cloths. Dispose of any replacement parts in a safe and environmen- tally-friendly manner.

  • Page 36: Information On Special Dangers

    Safety 2.13 Information on special dangers 2.13.1 Oil, grease and other chemical substances ENVIRONMENT! Danger due to incorrect handling of environmentally haz- ardous substances! Inappropriate handling of environmentally hazardous substances, especially incorrect disposal, can cause significant damage to the environment. —...

  • Page 37: Product Description

    Product Description Product Description Construction of the Börger machine Components: 1 Pump chamber 2 Intermediate chamber 3 Gear unit Construction: Quick-release cover Pump casing 2.1 Connection flange (inlet, outlet) Rotors Timing gear 4.1 Oil sight glass 4.2 Breather, oil filler for gear unit 4.3 Oil drain for gear unit 4.4 Two shafts with parallel axes;...

  • Page 38: Quick-Release Cover

    Product Description 3.1.1 Quick-release cover The Börger MIP principle (Maintenance in Place) starts with the quick-release cover (1). This cover enables easy access to the interior of the casing and to all parts subject to wear in the Börger machine. The pipes on the inlet and outlet can remain connected. The quick-release cover can be removed after loosening the four Ä...

  • Page 39: Rotors

    Product Description 3.1.3 Rotors A wide variety of different rotors are available for Börger rotary lobe pumps. NOTE! Material resistance of the rotors / lobe tips The rotor or lobe tip material used in your rotary lobe pump with regard to the resistance to the pumped medium is defined according to the attached data sheet.

  • Page 40: Timing Gear

    Depending on the ordered version, the drive shaft is installed in Fig. 1: Example: Classic FL series position 0 or position 1. The rotary lobe pump can also be delivered with two drive shafts, e.g.

  • Page 41: Intermediate Chamber (Quench)

    The contact area between the shaft and rotors is also lubricated with quench fluid, thus preventing corrosion. Fig. 2: Example: Classic FL series To compensate an increase in pressure at rising temperatures, the intermediate chamber features a breather at the side with a vent Ä...

  • Page 42: Designs, Mounting Positions

    Mounting position M1 Upright, feet at bottom, horizontal shafts Fig. 3: Example: Classic FL series Mounting position M2 www.boerger.de / www.boerger.com BA-Classic FL_en-US, 03.05.2018...
  • Page 43 Product Description Vertical, quick-release cover at bottom, feet at side, vertical shafts, drive shaft pointing upwards Fig. 4: Example: Classic FL series Mounting position M3 Upside-down, feet upwards, horizontal shafts Fig. 5: Example: Classic FL series Mounting position M5 Turned 90° to the left, feet to the right, horizontal shafts Fig.

  • Page 44: Pipe Connections On Inlet And Outlet

    Product Description Fig. 7: Classic FL series Oil level check on gear unit (oil sight glass / Fill hole on intermediate chamber oil dipstick) Breather for the intermediate chamber Oil drain for gear unit Intermediate chamber fill level indicator Drain from intermediate chamber Fill hole for gear unit, with breather system 3.1.8...
  • Page 45 Product Description — Short, straight pipe connector — 90° pipe bend — connection towards the front, back, top or bottom — Gooseneck version — connection towards the front, back or side — Double bend upwards — connection towards the front, back, top, bottom or side —...

  • Page 46: Units / Drive Options

    Product Description — Intake hopper on the inlet — For highly viscous but still fluid material, a 90° turned Börger machine can be equipped with an intake hopper on the inlet instead of a pipe connector 3.1.9 Units / drive options The majority of Börger machines are delivered as a complete unit, i.e.

  • Page 47: Options And Accessories

    Product Description Unit with hydraulic drive 1 Börger-Rotary lobe pump 2 Torsionally flexible coupling (does not apply for directly flanged hydraulic drive) 7 Hydraulic drive 9 Coupling lantern (adapter flange on directly flanged hydraulic drive) 11 Pipe connector (short, straight pipe connector with flange in this example) 3.1.10 Options and accessories...

  • Page 48: Operating Principle

    Product Description Operating principle 1 Suction chamber 2 Transfer from suction chamber to pressure chamber 3 Pressure chamber   Börger rotary lobe pumps are self-priming, valveless, positive dis- placement pumps. The rotors are turned in opposite directions via an external drive using two parallel shafts.

  • Page 49: Technical Data

    Product Description Technical data Börger machines are configured individually for the application requirements. This leads to a wide range of variations that have been optimized for specific applications. Therefore, only the data of some of the standard versions can be listed here as examples. Detailed specifications for your Börger machine or unit can be found in the data sheet and the individual dimensional drawing sent when the machine was ordered.
  • Page 50 Product Description Dimensions approx. [mm] approx. [inch] FL 518 FL 776 FL 1036 FL 518 FL 776 FL 1036 G½ G½ G½ G½ G½ G½ ØQ 0.75 0.75 0.75 9.21 9.21 9.21 approx. [kg] approx. [lb] FL 518 FL 776 FL 1036 FL 518 FL 776...
  • Page 51 Product Description FL 518 FL 776 FL 1036 DIN / DIN EN ANSI / ASME DIN / DIN EN ANSI / ASME DIN / DIN EN ANSI / ASME Stand ard: Dimen sion: — — — — (5") (6") (8") —...

  • Page 52: Performance Data And Maximum Loads

    Product Description Base frame Base frame Dimensions approx. [mm] approx. [inch] 1225 48.23 4.33 23.23 1135 44.69 1.77 0.71 Weight approx. [kg] approx. [lb] approx. Complete unit The dimensions can be found in the specific dimensional drawing created for the order. The dimensions and weights of the drive and gear unit etc.
  • Page 53 Product Description Pump output per revolution FL 518 approx. 5.6 l approx. 1.48 gal FL 776 approx. 8.4 l approx. 2.22 gal FL 1036 approx. 11.23 l approx. 2.97 gal The actual pump output depends on several factors, such as pres- sure, viscosity, speed and pump configuration.
  • Page 54 Product Description 12 bar (174 psi) subject to agreement 8 bar (116 psi) subject to agreement 6 bar (87 psi) subject to agreement Pipe connections Fig. 8: Example: Classic FL Forces and torques on metal pipe connectors (short, straight pipe connectors) Forces N max Torques Nm max Pipe nominal...

  • Page 55: Transportation, Storage And Installation

    Transportation, Storage and Installation Transportation, Storage and Installation Transportation Suspended loads! WARNING! Risk of fatal injury due to suspended loads! Loads can swing and fall during lifting operations. This can cause severe injury, including death. — Never stand under or within the swinging range of suspended loads.
  • Page 56 Transportation, Storage and Installation Personnel: Warehouse worker Protective equipment: Occupational safety clothing, chemical resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Hoists Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...

  • Page 57: As-Delivered Condition

    Transportation, Storage and Installation Overhead mounted drive assemblies can be transported safely using the method shown here, for example. As-delivered condition Personnel: Warehouse worker Protective equip- Occupational safety clothing, chemical ment: resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Ä Chapter —...

  • Page 58: Storage And Interim Storage

    Transportation, Storage and Installation Storage and interim storage 4.3.1 Storage NOTICE! Inadequate maintenance can result in malfunctions and damage! — When the machine is stored for longer periods, rotate the shafts several times after about six months (or more often, Ä...
  • Page 59 Transportation, Storage and Installation Personnel: Warehouse worker Protective equipment: Occupational safety clothing, chemical resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools, general Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...
  • Page 60 Transportation, Storage and Installation Personnel: Mechanics Qualified electricians Manufacturer Protective equip- Occupational safety clothing, chemical ment: resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools, general Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...

  • Page 61: Interim Storage

    Transportation, Storage and Installation 4.3.2 Interim storage For the interim storage of a used Börger machine, the following applies: Personnel: Mechanics Protective equipment: Occupational safety clothing, chemical resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools, general Ä Chapter —...

  • Page 62: Installation

    Transportation, Storage and Installation Installation Incorrect installation WARNING! Risk of fatal injury as a result of incorrect installation! Errors during installation may lead to extremely dangerous situa- tions and cause severe material damage. — Install the component parts professionally. Observe specified screw tightening torques.
  • Page 63 Transportation, Storage and Installation Personnel: Mechanics Protective equip- Occupational safety clothing, chemical ment: resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...
  • Page 64 Transportation, Storage and Installation Personnel: Mechanics Protective equip- Occupational safety clothing, chemical ment: resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools, general Hammer drill Torque wrench Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...
  • Page 65 Transportation, Storage and Installation Pipe connectors If your two-shaft Börger machine was delivered without pipe connectors (with standard rectangular flanges on the inlet and outlet), the appropriate pipe connectors must be attached as follows: Use: — Suitable flange screws — Suitable spring washers to secure the flange screws —...

  • Page 66: Positioning

    Transportation, Storage and Installation 4.4.2 Positioning Risk of frost NOTICE! Risk of damage caused by frost! Frost can cause damage to the Börger machine. — Protect the Börger machine and its connections against frost. Sufficient air circulation NOTICE! Sufficient air circulation at the drive! —...
  • Page 67 Transportation, Storage and Installation Versions with base frames NOTE! The nuts underneath the base frame must be accessible with a wrench from the front and back. If realignment is required or the machine is reinstalled on the base frame (e.g. following repairs or replacement), then it must be possible to hold the nuts in place with a wrench.

  • Page 68: Installing The Inlet And Outlet

    Transportation, Storage and Installation Example: anchor bolts Series Anchor bolts M12 x 130 mm (5.1 ") PL, CL, FL, EL M16 x 160 mm (6.3 ") M20 x 160 mm (6.3 ") Other versions — Mobile units must be operated on a solid surface and be secured in place.
  • Page 69 Transportation, Storage and Installation NOTICE! Risk of severe material damage due to cavitation! Cavitation can cause permanent damage to the Börger machine. — In order to avoid cavitation, the Börger machine should only have to negotiate a minimal priming height or no priming height at all.
  • Page 70 Transportation, Storage and Installation Personnel: Mechanics Protective equipment: Occupational safety clothing, chemical resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools, general Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...

  • Page 71: Aligning The Unit

    Transportation, Storage and Installation 4.4.4 Aligning the unit Version with torsionally After the Börger machine is installed, in order to rule out damage flexible coupling caused by displacement, you must check the alignment of the cou- pling on units mounted on a base frame that have gear motors. NOTE! Coupling guard —...
  • Page 72 Transportation, Storage and Installation Reattach the coupling guard (1) correctly. Retighten all fas- tening screws. Check the screws used to fasten the Börger machine to the base frame and retighten them, if necessary. Version with belt or chain The correct belt pre-tension or chain tension is necessary for cor- drive rect belt drive or chain drive functionality and a long service life for the V-belts/chains.

  • Page 73: Electrical, Hydraulic And Pto Shaft Connection

    Transportation, Storage and Installation Check the screws used to fasten the Börger machine to the base frame and retighten them, if necessary. 4.4.5 Electrical, hydraulic and PTO shaft connection EMERGENCY STOP system NOTE! Integration into the EMERGENCY STOP system A Börger machine must be integrated in an EMERGENCY STOP system.
  • Page 74 Transportation, Storage and Installation Electrical connection DANGER! Risk of fatal injury due to electric power! There is an immediate risk of fatal electric shock if live compo- nents are touched. Damage to the insulation of the individual components can be fatal. —...
  • Page 75 Transportation, Storage and Installation Personnel: Qualified electricians Protective equip- Occupational safety clothing, chemical ment: resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools for electrical work Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...
  • Page 76 Transportation, Storage and Installation Hydraulic connection DANGER! Risk of fatal injury due to hydraulic oil spurting out under pressure! Hydraulically actuated moving parts can cause severe injury. — Have all work on the hydraulic system performed by hydraulic specialists. — Depressurize the hydraulic system completely before starting work on it.
  • Page 77 Transportation, Storage and Installation Personnel: Mechanics Protective equipment: Occupational safety clothing, chemical resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools, general Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...
  • Page 78 Transportation, Storage and Installation Personnel: Mechanics Protective equipment: Occupational safety clothing, chemical resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools, general Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...

  • Page 79: Checks Before Commissioning

    Transportation, Storage and Installation Checks before commissioning Malfunctions NOTICE! Inadequate maintenance can result in malfunctions and damage! — When the machine is stored for longer periods, rotate the shafts several times after about six months (or more often, depending on the storage conditions), according to Ä...

  • Page 80: Checking Smooth Running Following Storage And Long Downtimes

    Transportation, Storage and Installation 4.5.1 Checking smooth running following storage and long downtimes Personnel: Mechanics Protective equipment: Occupational safety clothing, chemical resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools, general Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...

  • Page 81: Checking Readiness For Operation

    Transportation, Storage and Installation 4.5.2 Checking readiness for operation NOTE! Integration into the EMERGENCY STOP system A Börger machine must be integrated in an EMERGENCY STOP system. — It is only permissible to do without an emergency stop device if the emergency stop device would not reduce the stopping time and if it would not enable the special measures required to deal with the risk to be taken.
  • Page 82 Transportation, Storage and Installation Check the oil level in the gear unit of the Börger machine. On standing versions, the oil level must reach at least halfway up the oil sight glass. If this is not the case, the gear Ä...

  • Page 83: Checking The Flow Direction

    Transportation, Storage and Installation Ensure that the supply lines to the drive are connected and secured according to the relevant regulations. 10. Ensure that the unit is properly grounded. 11. Check that the pipe connectors are attached correctly and do not leak (torque for the connection between Börger Ä...
  • Page 84 Transportation, Storage and Installation Þ Required direction of rotation of Flow direction from right to left, when the upper shaft turns counter- the shaft / the fan wheel when clockwise looking at the drive: clockwise View of quick-release cover: View of drive with drive shaft at the top Þ...
  • Page 85 Transportation, Storage and Installation Personnel: Mechanics Qualified electricians Protective equip- Occupational safety clothing, chemical ment: resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools, general Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...

  • Page 86: Operation

    Operation Operation Improper operation WARNING! Risk of injury as a result of improper operation! Improper operation may cause severe injury and considerable material damage. — Prior to commissioning, ensure that all installation work is per- formed and completed as per the information and notes pro- vided in this manual.
  • Page 87 Operation Limits NOTICE! There is a danger of considerable material damage if the limits are not complied with! Failure to comply with the limits can cause permanent damage to the Börger machine and its components. — The values may neither exceed nor fall below the limits speci- Ä...
  • Page 88 Operation Blockage and imbalances NOTICE! Risk of material damage due to blockage and imbalances of the drive shaft! Inadequate cleaning and foreign bodies can cause permanent damage to your Börger machine. — Make sure that long-fibrous particles and other foreign bodies which might result in a blockage of the drive shaft do not enter the working chamber.

  • Page 89: Commissioning

    Operation Production residues! NOTE! Contamination caused by production residues! Börger machines may contain residues from the manufacturing process, e.g. grease or oil. Contamination caused by packaging and transport cannot be ruled out. — If necessary, thoroughly rinse the Börger machine with a suit- Ä...

  • Page 90: Test Run With Medium

    Operation NOTE! Rotary lobe pumps are self-priming positive displacement pumps. However, we recommend filling the pump with medium for suction operation before switching it on. This shortens the priming process and prevents dry run with increased wear. — Suitable equipment for filling and venting may be required in the suction and pressure lines.

  • Page 91: Complete Commissioning

    Operation — all errors have been rectified and — the functional checks without medium have shown the required smooth running and the desired direction of rotation, see Ä Chapter 4.5 “Checks before commissioning” on page 79. Adhere to the manufacturers' operating manuals for all attached control components.

  • Page 92: Continuous Operation

    Operation Continuous operation Personnel: Mechanics Qualified electricians Protective equip- Occupational safety clothing, chemical ment: resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...

  • Page 93: Downtimes

    Operation Downtimes Personnel: Operating person Protective equip- Occupational safety clothing, chemical ment: resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions” on page 30. Switch off the Börger machine (or the pumps or the gravity feed, depending on the system).

  • Page 94: Emergency Shut-Down

    Operation Emergency shut-down In cases of emergency, the Börger machine must be shut down as fast as possible, the energy supply must be switched off and pres- sure must be released. Please proceed as follows in emergencies: Personnel: Operating person Protective equip- Occupational safety clothing, chemical ment:...

  • Page 95: Malfunctions

    Operation Malfunctions Troubleshooting, mainte- nance and repair work WARNING! Risk of injury due to inadequate troubleshooting, mainte- nance and repair work! Inadequate troubleshooting, maintenance and repair work can lead to severe injury and significant damage to property. — Ensure sufficient installation space before commencing work. —...
  • Page 96 Operation Delayed shut-down NOTICE! Risk of severe material damage due to a delayed shut-down in the event of a malfunction! A delayed shut-down in the event of malfunction can cause per- manent damage to the Börger machine. — In the event of a malfunction, shut down the Börger machine and all upstream and downstream system components imme- diately until the cause has been rectified.
  • Page 97 Operation Fault description Cause Remedy Personnel Incorrect parameteriza- — Correct the setting Qualified tion of the control unit or electricians — Check that the frequency con- frequency converter verter is suitable (it must emit a constant torque) Pressure line (side of —...
  • Page 98 Operation Fault description Cause Remedy Personnel — Check the pipes for damage and rectify, if necessary — Rule out any leaks on compo- nents (pressure gauges, ball valves etc.) Suction line completely — Lower the pump* and prevent Mechanics empty emptying of the pump chamber, e.g.
  • Page 99 Operation Fault description Cause Remedy Personnel Rotors worn as part of — Replace the rotors Mechanics regular use Wear on casing liners or — Replace worn parts Mechanics pump casing The pump emits rat- Speed too high*, pump — Reduce the speed Mechanics tling noises chambers only partially...
  • Page 100 Operation Fault description Cause Remedy Personnel Foreign bodies in the — Remove foreign bodies Mechanics pump chamber — Install a macerator (Multi- crusher, Multichopper) and a stone trap upstream, if neces- sary Diameter of the suction — Adjust the pipe diameter to the Mechanics line (side of inlet) too pump output of the rotary lobe...
  • Page 101 Operation Fault description Cause Remedy Personnel Pumped volume Suction height too large — Reduce the suction height Mechanics below the nominal (> 8 m / 26.25 ft)* (lower the pump)* value Diameter of the suction — Adjust the pipe diameter to the Mechanics line (side of inlet) too pump output of the rotary lobe...
  • Page 102 Operation Fault description Cause Remedy Personnel Fluid escapes from Temperature-related — Drain some quench fluid Mechanics the vent hole and/or expansion with too — Adhere to temperature limits the safety opening much fluid in inter- — Use suitable quench fluid mediate chamber Rotor seal damaged —...
  • Page 103 Operation NOTE! Decreasing pump output! In the event of decreased pump output, Börger GmbH rec- ommends first checking the condition of the rotors. Replace the rotors when they exhibit signs of significant wear. — If these measures are not successful and the original pump output is still not reached following the installation of new rotors, the casing protection plates must be inspected.

  • Page 104: Measures Following On Demand Work

    Operation Measures following on demand work! Following completion of the work and before starting the unit, carry out the following steps: Personnel: Mechanics Protective equipment: Occupational safety clothing, chemical resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools, general Ä...

  • Page 105: Maintenance And Repairs

    Maintenance and Repairs Maintenance and Repairs Ä Chapter 6 “Maintenance and Repairs” on page 105 is divided into sections on machine care, maintenance and inspection, and repairs. The instructions described in this chapter are to be understood as the minimum requirements. Depending on the operating conditions, further work may be nec- essary to maintain the Börger machine in an optimum condition.

  • Page 106: Machine Care

    Maintenance and Repairs Personnel: Mechanics Qualified electricians Protective equip- Occupational safety clothing, chemical ment: resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...
  • Page 107 Maintenance and Repairs NOTICE! Improper cleaning of the Börger machine can lead to mal- functions and damage! — Do not use water jets. — Do not use aggressive cleaning agents, solvents or sand- paper, as these can damage the metallic and plastic surfaces, casing coating and seals.

  • Page 108: Cleaning The Outside

    Maintenance and Repairs 6.1.1 Cleaning the outside Personnel: Operating person Protective equip- Occupational safety clothing, chemical ment: resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Light respiratory protection Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...

  • Page 109: Pressure Relief

    Maintenance and Repairs 6.1.2 Pressure relief CAUTION! Health hazard due to residues of dangerous medium inside and on the Börger machine! There is an increased health hazard from contact with the medium and contaminated components. Generally, the following applies: — When using dangerous or health-endangering media, take all necessary safety measures when performing work on the Börger machine.
  • Page 110 Maintenance and Repairs Personnel: Operating person Protective equipment: Occupational safety clothing, chemical resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools, general Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...

  • Page 111: Cleaning The Inside

    Maintenance and Repairs 6.1.3 Cleaning the inside WARNING! Risk of serious injuries caused by liquid spouting out or escaping gases! Gases or liquids may escape uncontrollably from seals and screw connections. Especially when flange connections are released and maintenance openings are opened, pressurized liquid can spout out at the cover.
  • Page 112 Maintenance and Repairs ENVIRONMENT! Danger due to incorrect handling of environmentally haz- ardous substances! Inappropriate handling of environmentally hazardous substances, especially incorrect disposal, can cause significant damage to the environment. — Especially water-polluting materials such as grease and lubri- cating oil must not pollute the soil or enter the sewage system during installation, repair and maintenance work.
  • Page 113 Maintenance and Repairs — To the extent necessary, amply secure the surrounding area when performing maintenance. Cordon off the working area with a red and white safety chain and a warning sign. — Relieve the pressure in the Börger machine according to Ä...

  • Page 114: Maintenance And Inspection

    Maintenance and Repairs Maintenance and inspection 6.2.1 Maintenance and inspection plan NOTICE! Risk of material damage due to improper maintenance! — Also observe the maintenance intervals detailed in the oper- ating manuals for the drive gear unit, motor etc., which are included in the appendix.
  • Page 115 Maintenance and Repairs Interval Maintenance work Personnel weekly Checking the functions and flow rate Operating person Ä Chapter 5.5 — suitable measures as described in “Malfunctions” on page 95 — Replace damaged parts, if necessary monthly Checking the oil level of the machine gear unit on the oil Operating person sight glass Manufacturer...

  • Page 116: Lubricant Fill Level And Changing The Lubricants

    Maintenance and Repairs 6.2.2 Lubricant fill level and changing the lubricants NOTICE! Risk of severe material damage if the quench fluid is not compatible with the medium! Loss of seal function if the quench fluid is not compatible with the medium may lead to severe material damage.
  • Page 117 Maintenance and Repairs ENVIRONMENT! Danger due to incorrect handling of environmentally haz- ardous substances! Inappropriate handling of environmentally hazardous substances, especially incorrect disposal, can cause significant damage to the environment. — Especially water-polluting materials such as grease and lubri- cating oil must not pollute the soil or enter the sewage system during installation, repair and maintenance work.
  • Page 118 Maintenance and Repairs Personnel: Operating person Protective equipment: Occupational safety clothing, chemical resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools, general Ä Chapter — Read and follow the safety instructions detailed in 2.12 “Safety instructions for maintenance and rectifying mal- functions”...
  • Page 119 Maintenance and Repairs In this case: Expansion of the gear oil caused by the temperature cannot be compensated. The operating tempera- ture must not exceed the temperature specified in the order. For submerged machines: approx. 10 cm (3.94'') below the edge of the extension pipe Correcting the lubricant fill levels Personnel:...
  • Page 120 Maintenance and Repairs Filling: Remove the closure from the fill hole. Fill the lubricant up to the optimum fill level having regard to the information in Ä Chapter 9.8 “Lubricant list” on page 187. Properly close the fill hole with the closure removed previ- ously.
  • Page 121 Maintenance and Repairs — Read and follow the safety instructions detailed in Ä Chapter 2.12 “Safety instructions for maintenance and rectifying mal- functions” on page 30. — Shut down the Börger machine and downstream and upstream Ä Chapter 5.3 “Down- system components as described in times”...
  • Page 122 Maintenance and Repairs Design / Gear unit Intermediate chamber (approx.) Mounting position (approx.) FL... 2.4 l 1036 (0.634 gal) 3.4 l (0.898 gal) 3.4 l 4.8 l M5, M6 turned 90° (0.898 gal) (1.270 gal) 2.4 l 1036 (0.634 gal) www.boerger.de / www.boerger.com BA-Classic FL_en-US, 03.05.2018...

  • Page 123: Repairs

    Maintenance and Repairs Repairs Health protection CAUTION! Health hazard due to residues of dangerous medium inside and on the Börger machine! There is an increased health hazard from contact with the medium and contaminated components. Generally, the following applies: — When using dangerous or health-endangering media, take all necessary safety measures when performing work on the Börger machine.
  • Page 124 Maintenance and Repairs — Relieve the pressure in the Börger machine according to Ä Chapter 6.1.2 “Pressure relief” on page 109. — Clean the interior of the Börger machine as described in Ä Chapter 6.1.3 “Cleaning the inside” on page 111. Thoroughly clean all parts and the working chamber of the machine before reinstalling removed parts.

  • Page 125: Opening And Closing The Quick-Release Cover

    Maintenance and Repairs 6.3.2 Opening and closing the quick-release cover Fig. 9: Example: Classic FL series 1 Ring nut 2 Quick-release cover 3 Cover-side casing protection plate 4 O-ring 5 Stud screw Personnel: Mechanics Protective equipment: Occupational safety clothing, chemical...
  • Page 126 Maintenance and Repairs — Secure the Börger machine against unauthorized or uncon- Ä Chapter 2.7 “Securing the trolled reactivation as described in machine against restart” on page 24 — To the extent necessary, amply secure the surrounding area when performing maintenance. Cordon off the working area with a red and white safety chain and a warning sign.
  • Page 127 Maintenance and Repairs 12. Clean the cover-side casing protection plate (3) and check the casing protection plate (3) for wear. If the cover-side casing protection plate (3) exhibits signs of wear, the plate (3) has to be turned and inserted with the unused side.

  • Page 128: Rotors, Removal And Replacement

    Maintenance and Repairs 6.3.3 Rotors, removal and replacement NOTICE! Risk of damage due to switching on the machine without rotors being installed properly! If the rotors are not properly installed, the parallel key cannot reli- ably fix the rotating seal holding bushes. This may cause perma- nent damage to the rotary lobe pump.
  • Page 129 Maintenance and Repairs Premium rotor Dual-lobe, linear — Types JS, JE, — Steel, stainless steel Pos. 9.6 in the spare parts list Orbit rotor Dual-lobe, linear — Type P — Steel, stainless steel Pos. 9.8 in the spare parts list Personnel: Mechanics Protective equip-...
  • Page 130 Maintenance and Repairs — Clean the interior of the Börger machine as described in Ä Chapter 6.1.3 “Cleaning the inside” on page 111. — Open the quick-release cover in accordance with Ä Chapter 6.3.2 “Opening and closing the quick-release cover” on page 125.
  • Page 131 Maintenance and Repairs For rotors made from steel / stainless steel: — In each case, remove the sealing washer (2). — In each case, remove the cover disk (3) and O-ring (4) using a suitable hook or two slotted screwdrivers. —...
  • Page 132 Maintenance and Repairs Clean and oil the carrier shafts [W]. NOTE! Some quench fluid may escape from between the rotating seal holding bushes [AT] and carrier shafts [W] as a result of the normal lubricating function. This is not a malfunction. Check the O-rings (7) on the rotating seal holding bushes and replace them when necessary.
  • Page 133 Maintenance and Repairs NOTE! Use only rotors made from suitable materials and of the cor- rect type. 10. Clean the fit bores of the rotors. 11. Lubricate the fit bores of the rotors with a suitable oil/lubricant that is compatible with the medium, and also lubricate the O- ring (7) of the rotating holding bush if its resistance allows this.
  • Page 134 Maintenance and Repairs 15. Make sure that the upper parallel key (6) is still at 12 o'clock, i.e. the carrier shaft has not been moved. 16. Insert the rotor with clockwise screw profile [R] at the top. 17. For rotors made from steel or stainless steel: —...
  • Page 135 Maintenance and Repairs 20. Check that the installed rotors run smoothly. The easiest way of doing this is by turning the drive shaft clockwise with an appropriate amount of force using a hexagon socket wrench or a ratchet. If correct true-running is not obtained, the cause must be determined and the installation must be corrected.
  • Page 136 Maintenance and Repairs Tri-lobe, screw profile, — Steel rotor body — Type G — Removable lobe tips Pos. 9.1 in the spare parts list Tri-lobe, screw profile, — Stainless steel rotor body — Type H — Removable lobe tips Pos. 9.1 in the spare parts list Maintaining, removing and replacing rotors with removable lobe ®...
  • Page 137 Maintenance and Repairs Linear rotors: T-plug Auxiliary disassembly thread Spacer (only on linear rotors for type Clamping wedge FL776) Screws Hexagon socket head cap screw Lobe tip, two parts in case of FL1036 Clamping wedge Rotor body Clamping part NOTICE! Risk of material damage when using wetted parts made of non-suitable material! Compare the quality symbol [b] on the lobe tips that describes the...
  • Page 138 Maintenance and Repairs a Marked R for clockwise screw profile, L for counter-clockwise screw profile b Example for quality symbol describing the material, see data sheet. NOTE! A pair of screw rotors consists of one rotor with a counter-clock- wise screw profile and one with a clockwise screw profile. The removable lobe tips are also configured accordingly for clockwise and counter-clockwise screw rotors and marked with R (clockwise) or L (counter-clockwise) [a].
  • Page 139 Maintenance and Repairs — To the extent necessary, amply secure the surrounding area when performing maintenance. Cordon off the working area with a red and white safety chain and a warning sign. — Relieve the pressure in the Börger machine according to Ä...
  • Page 140 Maintenance and Repairs Loosen the hexagon socket head cap screw (3) using a hex- agon socket wrench and remove the screw (3) with the clamping wedge (4). Screw a suitable threaded rod with slide hammer into the thread (6) in the clamping part (5). Remove the lobe tip (9) with clamping part (5) using the slide hammer.
  • Page 141 Maintenance and Repairs 14. Screw a clamping part (5) onto each new lobe tip (9) with a suitable torque for the screws (8). FL518 M8 steel screws, 10.9 25 Nm (221 in-lbs) M8 stainless steel screws, A4-70 20 Nm (177 in-lbs) FL776, M10 steel screws, 10.9 50 Nm (443 in-lbs)
  • Page 142 Maintenance and Repairs 21. Tighten the hexagon socket head cap screws (3) with a torque wrench: M10 steel screws, 10.9 50 Nm (443 in-lbs) M10 stainless steel screws, A4-70 40 Nm (354 in-lbs) 22. For FL1036 with linear rotors: — Install the front lobe tips (9) one after the other. —...
  • Page 143 Maintenance and Repairs 25. Check that the installed rotors run smoothly. The easiest way of doing this is by turning the drive shaft clockwise with an appropriate amount of force using a hexagon socket wrench or a ratchet. If correct true-running is not obtained, the cause must be determined and the installation must be corrected.
  • Page 144 Maintenance and Repairs Removing and replacing ® the MIP rotors 1 Rotor fastening screw 2 Sealing washer 3 Cover disk 4 O-ring of cover disk 5 Rotor body 6 Lobe tip 7 O-ring of rotating holding bush 8 Parallel key 9 Grub screws W Carrier shaft www.boerger.de / www.boerger.com...
  • Page 145 Maintenance and Repairs Personnel: Mechanics Protective equip- Occupational safety clothing, chemical ment: resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: W... rotor puller for auxiliary puller Z... auxiliary puller, tri-lobe Torque wrench NOTICE! Risk of material damage if the rotating seal holding bushes are adjusted incorrectly! —...
  • Page 146 Maintenance and Repairs — To the extent necessary, amply secure the surrounding area when performing maintenance. Cordon off the working area with a red and white safety chain and a warning sign. — Relieve the pressure in the Börger machine according to Ä...
  • Page 147 Maintenance and Repairs 13. Clean and oil the carrier shafts [W]. NOTE! Some quench fluid may escape from between the rotating seal holding bushes and carrier shafts as a result of the normal lubricating function. This is not a malfunction. 14.
  • Page 148 Maintenance and Repairs 21. Use new sealing washers (2) for the rotor fastening screws (1). 22. Screw in the hexagon socket head cap screws (1) using a suitable hexagon socket wrench and tighten them (1) with a torque wrench. M20 steel screws, 10.9 200 Nm (1,770 in-lbs) M20 stainless steel screws A4-70, A5-70 200 Nm (1,770 in-lbs)

  • Page 149: Replacing The Mechanical Seal

    Maintenance and Repairs 6.3.4 Replacing the mechanical seal 1 O-ring 2 Rotating seal holding bush 3 Keyway 4 Seal faces 5 O-ring 6 Lip seal 7 Gear-side casing protection plate 8 Stationary seal holding bush 9 Parallel key W Shaft Personnel: Mechanics Protective equipment:...
  • Page 150 Maintenance and Repairs — Secure the Börger machine against unauthorized or uncon- Ä Chapter 2.7 “Securing the trolled reactivation as described in machine against restart” on page 24 — To the extent necessary, amply secure the surrounding area when performing maintenance. Cordon off the working area with a red and white safety chain and a warning sign.
  • Page 151 Maintenance and Repairs In each case, unscrew the rotating seal holding bush (2) using the special tool (M) and pull it off the shaft. Remove the seal face (4) with O-ring (5) out of the corre- sponding rotating seal holding bush (2). Remove the seal faces (4) with O-rings (5) out of the sta- tionary seal holding bushes (8) remaining in the Börger machine using a suitable tool (e.g.
  • Page 152 Maintenance and Repairs NOTICE! Risk of material damage due to incorrect handling of mechanical seals! Make sure not to damage the sealing surfaces of the new seal faces. — The sealing surfaces must be clean and should not be scratched. 12.
  • Page 153 Maintenance and Repairs 14. Press one seal face (4) with O-ring (5) into each rotating seal holding bush (2) using the push-in tool for mechanical seals (M). 15. Press both remaining seal faces (4) with O-rings (5) into the stationary seal holding bushes (8) using the push-in tool for mechanical seals (M).
  • Page 154 Maintenance and Repairs 17. Setting of the rotating seal holding bush in case of rotor replacement Example of PL 100 Premium rotor Pump casing depth A = 55 mm (2,2 inch) — 1 - Pump casing — 2 - Casing protection plate —...
  • Page 155 Maintenance and Repairs Rotor steel / stainless steel Rotor, rubber-coated — with edge Setting — No resetting of the rotating seal holding bush required — (Rotating seal holding bush flush with casing protection plate) Rotor steel / stainless steel Rotor, rubber-coated —...
  • Page 156 Maintenance and Repairs 18. Flush installation Screw in the rotating seal holding bush (2) flush with the gear-side casing protection plate (7) and then unscrew it until Ä Further the first groove is aligned with the keyway, see information on page 149, step 20. A.
  • Page 157 Maintenance and Repairs 21. Fit the new O-ring (1) onto the rotating seal holding bush (2). Only reuse an old O-ring when damage can be completely ruled out. NOTE! Installing the O-ring Depending on the installation conditions, it might be easier to push the O-ring (1) into the groove of the rotating seal holding bush (2) prior to screwing in the rotating seal holding bush using the Multitool (12).
  • Page 158 Maintenance and Repairs 26. Before releasing the Börger machine, check once again that it runs smoothly by switching the drive on briefly. If correct true-running is not obtained, the cause must be determined and the installation must be corrected. 27. Fill the intermediate chamber and close the fill hole in accord- ance with Ä...

  • Page 159: Replacing The Casing Liners

    Maintenance and Repairs 6.3.5 Replacing the casing liners Hexagon socket head cap screw O-ring Sealing washer Casing liner Clamping part O-ring groove Personnel: Mechanics Protective equipment: Occupational safety clothing, chemical resistant Safety shoes Safety gloves, chemical-resistant Safety goggles Special tool: Tools, general Torque wrench —...
  • Page 160 Maintenance and Repairs — Relieve the pressure in the Börger machine according to Ä Chapter 6.1.2 “Pressure relief” on page 109. — Open the quick-release cover in accordance with Ä Chapter 6.3.2 “Opening and closing the quick-release cover” on page 125. —...
  • Page 161 Maintenance and Repairs Pull out the casing liner (5) using a pair of tongs (e.g. pipe tongs). Sealing washers (2) are located under the hexagon socket head cap screws (1). Replace them when damage cannot be completely ruled out. For this purpose, remove the clamping parts (3) in case of removed rotors.
  • Page 162 Maintenance and Repairs 14. Attach the cover-side casing protection plate and quick- Ä Chapter 6.3.2 “Opening and closing the release cover, see quick-release cover” on page 125. Clamping part torque FL 518 M12 steel screws, 10.9 100 Nm (885 in-lbs) M12 stainless steel screws A4-70, A5-70 60 Nm (531 in-lbs)

  • Page 163: Replacing The Gear-Side Casing Protection Plate

    Maintenance and Repairs 6.3.6 Replacing the gear-side casing protection plate Fig. 11: Example: casing protection plate, two parts 1 Rotating holding bush O-ring 2 Countersunk screw 3 Gear-side casing protection plate, two parts 4 Jacking thread Personnel: Mechanics Protective equip- Occupational safety clothing, chemical ment: resistant...
  • Page 164 Maintenance and Repairs — To the extent necessary, amply secure the surrounding area when performing maintenance. Cordon off the working area with a red and white safety chain and a warning sign. — Depressurize and clean the interior of the Börger machine as Ä...

  • Page 165: Other Repairs

    Maintenance and Repairs 6.3.7 Other repairs If repairs to your Börger machine are required that are not covered by the described repair and maintenance measures, we recom- mend contacting Börger customer service. The factory can only accept repair orders if a completed safety cer- tificate / declaration of decontamination accompany the device submitted for repair, as well as any necessary safety data sheets for the medium and / or cleaning agent.

  • Page 166: Queries

    Maintenance and Repairs Take the unit into operation again according to Ä Chapter 5.2 “Continuous operation” on page 92. 6.3.9 Queries Börger machines are easy to maintain. We hope that we have clearly described all the relevant operating steps in this operating manual.

  • Page 167: Disposal

    Disposal Disposal Environmental protection ENVIRONMENT! Danger due to incorrect handling of environmentally haz- ardous substances! Inappropriate handling of environmentally hazardous substances, especially incorrect disposal, can cause significant damage to the environment. — Especially water-polluting materials such as grease and lubri- cating oil must not pollute the soil or enter the sewage system during installation, repair and maintenance work.

  • Page 168: Metals

    Disposal Metals Sort and separate different metal types. Dispose of these metals according to the legal requirements through authorized waste disposal companies/authorities. Electrical and electronic waste Electrical and electronic waste must be disposed of separately. Electrical and electronic waste must not be disposed of with domestic waste.

  • Page 169: Accessories

    Accessories Accessories The range of accessories supplied by Börger GmbH is as multi- faceted as the areas of application for Börger machines. Only the most frequently requested equipment can be mentioned below. If your Börger machine was delivered with accessories, the corresponding operating manuals can generally be found in the appendix or in the packaging of the units, if delivered as originally packed.

  • Page 170: Pressure Monitoring Devices As Overpressure Protection

    Accessories If the temperature in the pump chamber rises to a preset value due to a lack of pumped medium, the rotary lobe pump / system equipped with a PT100 temperature sensor is switched off by means of a control unit. This then prevents the rotary lobe pump from running dry.

  • Page 171: Level Monitor With Float Switch

    Accessories 8.2.4 Level monitor with float switch Float switches and floating magnetic switches are used for moni- toring or controlling the fill level, and can also be used for dry run protection (depending on the version). Fig. 13: Example: float switch Auger feed An auger feed with a feed hopper at the inlet of the Börger machine allows non-flowing or hardly flowing media that are just...

  • Page 172: Appendix

    Appendix Appendix Data sheet The data sheet is enclosed separately with the operating manual. The data sheet contains all relevant data for your Börger machine. Especially consider the operating conditions and limits mentioned in the data sheet. They may deviate from the information men- tioned in this operating manual if the machine has special equip- ment.
  • Page 173 Appendix Replacing the lobe tips Pos. no. Designation Quantity Unit Lobe tip, for screw rotors 9.1b 6/12 piece(s) 9.2b — 3x counter-clockwise screw profile — 3x clockwise screw profile 9.1f T-plug piece(s) 9.2f 9.1g Spacer piece(s) 9.2g O-ring for quick-release cover piece(s) Replacing the rotors Pos.
  • Page 174 Appendix Pos. no. Designation Quantity Unit Sealing washer for hexagon socket head cap screw on 0/4/8 piece(s) clamping part O-ring for quick-release cover piece(s) O-ring for rotating holding bush piece(s) O-ring for cover disk piece(s) Screw for casing protection plate piece(s) Sealing washer piece(s)

  • Page 175: Assembly Drawing

    Appendix Assembly drawing The assembly drawing shows the positions of the spare parts as Ä Chapter 9.4 “Spare parts list” on page 177. described in BA-Classic FL_en-US, 03.05.2018 www.boerger.de / www.boerger.com...

  • Page 176: Rotary Lobe Pump

    Appendix 9.3.1 Rotary lobe pump www.boerger.de / www.boerger.com BA-Classic FL_en-US, 03.05.2018...

  • Page 177: Spare Parts List

    Appendix Spare parts list WARNING! Risk of injury when using unsuitable spare parts! The use of unsuitable spare parts can cause malfunctions which can lead to severe injury, including death, and to significant mate- rial damage. — Only use suitable spare parts. —...
  • Page 178 Appendix Quantity FL... Pos. Item description 1036 Casing Quick-release cover for pump casing Rotor body, tri-lobe, screw profile, ccw 9.1a Rotor body, tri-lobe, screw profile, cw Lobe tip, screw profile, ccw 9.1b Lobe tip, screw profile, cw Clamping part for lobe tip consisting of –...
  • Page 179 Appendix Quantity FL... Pos. Item description 1036 Hexagon socket head cap screw, DIN EN ISO 4762, for clamping 0 / 4 0 / 8 0 / 8 part pos. 12b Sealing washer 0 / 4 0 / 8 0 / 8 Stationary seal holding bush Rotating seal holding bush with thread Mechanical seal...

  • Page 180: Tools / Installation Aid

    Appendix 9.4.1 Tools / installation aid The tools below are needed to carry out the required checks and correct installation: Standard tools Tools for electrical work — These tools shall comply with the international standard IEC 60900 (identical to EN 60900 for Europe and DIN EN 60900 for Germany).
  • Page 181 Appendix Special tools Hammer drill — A hammer drill is a power tool to drill holes into mineral mate- rial, e.g. stone or concrete. Through the impact, the cutting edge of the drill pulverizes the material Hoists Lifting and slinging gear must be designed and dimensioned ade- quately according to the particular hazard and the loads occurring during transport.
  • Page 182 Appendix — for all rubber-coated rotors — 2x for screw rotors W... rotor puller for auxiliary puller Dual-lobe rotors — The W... rotor puller in combination with the Z... auxiliary puller and two suitable screws (not included in the scope of supply) is to be used for dual-lobe rotors with cover disk.

  • Page 183: Parallel Keys

    Appendix Parallel keys The following parallel key lengths must be adhered to and checked. NOTICE! Risk of material damage when operated with an incorrect or damaged parallel key! Imprecise parallel key lengths can lead to misalignment of the rotating holding bush and can cause mechanical damage to the Börger machine or to the complete unit.
  • Page 184 Appendix Customer: Börger order confirmation no.: Machine number: Type code: Your project: Order number: Commissioning date: Delivery date: Carried out by: Checked by: Test point (date/signature) (date/signature) 1 Operating manual and appendices read and understood Application data and operating parameters according to data sheet correspond to application 3 Base frame fixed correctly to solid, even surface Coupling alignment within the permitted tolerance, coupling...

  • Page 185: Eu Declaration Of Conformity / Eu Declaration Of Incorporation

    Appendix EU Declaration of Conformity / EU Declaration of Incorporation 9.7.1 EU Declaration of Conformity EU Declaration of Conformity Börger GmbH | Benningsweg 24 | 46325 Borken-Weseke | Germany We hereby declare that the following products: Product description: Rotary lobe pump Product line: BLUEline Type descriptions:...

  • Page 186: Eu Declaration Of Incorporation

    Appendix 9.7.2 EU Declaration of Incorporation EU Declaration of Incorporation Börger GmbH | Benningsweg 24 | 46325 Borken-Weseke | Germany We hereby declare that the following products: Product description: Rotary lobe pump Product line: BLUEline Type descriptions: AL, PL, CL, FL, FLA, EL, XL Version: Classic, Select, Protect Serial number:...

  • Page 187: Lubricant List

    Appendix Lubricant list Area of validity Unless subject to special agreements, this lubricant list is part of the operating manual and applies to all standard Börger pump ver- sions, Powerfeed units, macerating units, Bioselect units and sub- mersible mixers. Deviations can be agreed upon individually for special applica- tions.

  • Page 188: Börger Gear Units

    Appendix 9.8.1 Börger gear units Oil quality Only oils containing active substances for improving corrosion pro- tection and aging resistance and reducing wear in gear units are permitted for use in Börger gear units. Additionally, the gear oils must also meet the following quality requirements: —...

  • Page 189: Buffer Fluid

    Appendix The purity of the lubricant influences the service life of the oil and gear unit, plus general operating safety. Therefore, always ensure that the gear unit contains clean oil! Instructions for changing the oil/lubricant contained in the oper- ating manual of the Börger device must be strictly adhered to. The amount of remaining used oil in the gear unit must be kept as low as possible, even when the same oil type is used for the oil change.

  • Page 190: Oil Properties

    Appendix NOTICE! Risk of material damage when using wrong lubricants! Due to the possibility, though unlikely, of buffer fluid entering the pump/cutting chamber and thus intruding on the process itself, the buffer fluid must be compatible with the pumped/flow medium in addition to the other materials (O-rings).
  • Page 191 Appendix Compared to mineral oils, synthetic oils can be used in a wider operating temperature range, whereupon the temperature-related viscosity deviation is lower (higher viscosity index). In addition, synthetic oils have a higher thermal stability and a higher ignition point. With medium temperatures of more than 80°C (176°F) or ATEX units, you should therefore use synthetic, high-quality indus- trial gear oil with an ignition point above 200°C (392°F) in the...

  • Page 192: Oil Types

    Appendix 9.8.4 Oil types Suitable lubricants for Börger gear units Mineral lubricants Manufacturer Designation Type Viscosity [T=40°C (104°F)] Aral Degol Energol GR-XP Castrol Alpha Chevron Meropa Mobil Mobilgear Lukoil Stello HAST Shell Omala S2 G Texaco Meropa Petronas Gear Total Carter Synthetic lubricants Manufacturer...
  • Page 193 Appendix Lubricants suitable as buffer fluid Mineral lubricants Manufacturer Designation Type Viscosity [T=40°C (104°F)] Aral Vitam Energol Castrol Magna Chevron Meropa Mobil Mobilgear Lukoil Geyser Shell Omala S2 G Texaco Meropa Petronas Gear Lubriplate Total Carter Synthetic lubricants Manufacturer Designation Type Viscosity [T=40°C (104°F)] Aral...
  • Page 194 Appendix Food-safe lubricants Manufacturer Designation Type Viscosity Application temper- Notes [T=40°C ature (104°F)] LANXESS/Dow Propylene glycol pure 19.5 up to 100°C (212°F) USP/EP LANXESS/Dow Water/Glycerin 70%/30% up to 60°C (140°F) USP/EP Klüber Sugar dissolving NH1 6-10 12.0 up to 60°C (140°F) USDA-H1 Klüber Paraliq...

  • Page 195: Oil Filling Quantity Of The Börger Units

    Appendix 9.8.5 Oil filling quantity of the Börger units Rotary lobe Gear unit Intermediate chamber pumps - BLUEline Design (Code) Design (Description) approx. [l] approx. approx. approx. - Multi- [gal] [gal] crusher M1/M3 standing / upside-down 0.10 0.08 turned 90° 0.10 0.08 vertical...
  • Page 196 Appendix Multichopper Gear unit Intermediate chamber P series Design (Code) Design (Description) approx. [l] approx. approx. approx. [gal] [gal] M1/M3 standing / upside-down does not apply 0.21 turned 90° does not apply 0.21 vertical does not apply does not apply Powerfeed Gear unit Intermediate chamber...

  • Page 197: Lubricant Orders

    Appendix 9.8.6 Lubricant orders NOTE! Lubricant orders You can order lubricants by quoting the article number from the enclosed spare parts list. You can also quote the type code and serial number on the nameplate of the Börger machine when ordering. Börger will then obtain the information for the appropriate lubricants for you from the production documents of your machine.

  • Page 198: Customer Approval For Special Lubricants (Example)

    Appendix 9.8.7 Customer approval for special lubricants (example) Kunde: Mustermann Synthecta AG – Borken-Weseke (D) Customer: Produktbezeichnung: Rotary lobe pump Type of machinery: Produktlinie: BlueLine Product line: Typenbezeichnungen: PL 200 Model: Ausführung: Classic Version: Auftragsnummer: 16002546 Order No.: Medientemperatur [°C]: 20 - 58 Fluid temperature [°C]: Drehzahl [U/min]:...

  • Page 199: Additional Documentation

    Appendix Additional documentation — Further, separate supplementary operating manuals for special versions are also part of this operating manual. 9.10 Supplier documentation — You must completely read the separate supplier documentation and consider it accordingly. BA-Classic FL_en-US, 03.05.2018 www.boerger.de / www.boerger.com...

  • Page 200: Index

    Index Index Complete commissioning ....91 Components ......37 Accessories .
  • Page 201 Index Dimensions ......49 Instruction ......10 Disposal .
  • Page 202 Index Pressure relief ..... . 109 Test run ......90 Maintenance and Repairs .
  • Page 203 Index Securing the machine against restart . . . 24, 30 Measures following repairs ... 165 Service ....... . 3 Mechanical seal .
  • Page 204 Index V-belt tension ......72 Wear parts ......106 www.boerger.de / www.boerger.com BA-Classic FL_en-US, 03.05.2018...

This manual is also suitable for:

Classic fl 518Classic fl 776Classic fl 1036

Table of Contents

Save PDF