Alfa Laval ALP 100 Operating Instructions Manual
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Alfa Laval ALP 100 Operating Instructions Manual

Screw pumps magnetic coupling m-type
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Screw pumps ALP Sizes 0100–0280 Magnetic
coupling M-type
Operating Instructions
Lit. Code
200007725-1-EN-GB
Manual No.
9062571 02
Component Description
BRITISH ENGLISH

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Summary of Contents for Alfa Laval ALP 100

  • Page 1 Screw pumps ALP Sizes 0100–0280 Magnetic coupling M-type Operating Instructions Component Description Lit. Code 200007725-1-EN-GB Manual No. 9062571 02 BRITISH ENGLISH...
  • Page 2 © Alfa Laval Corporate AB 2022-09 This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval Corporate AB. No part of this document may be copied, re-produced or transmitted in any form or by any means, or for any purpose, without Alfa Laval Corporate AB’s prior express written permission. Information and services provided in this document are made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these services for any purpose.

  • Page 3: Table Of Contents

    Contents 1 Warning signs in text .................... 7 Warning signs ......................7 2 About this document ..................... 9 General information....................9 Target groups ......................9 Symbols........................9 Associated documents....................9 3 Safety ..........................11 Proper use ......................11 Safety information....................12 Safety instructions for magnetic coupling systems..........13 4 Labelling ........................15 Type code .......................15...
  • Page 4 7.4.2 Disposing of the pump ................31 8 Installation, removal and connection ............33 Safety instruction on installation, removal and connection........33 Installation ......................33 Installing the pump ....................34 Protect the pump against soiling ................35 8.4.1 Connecting the pump to the pipe system...........35 8.4.2 Connecting the motor ................36 Removing the pump ....................
  • Page 5 12.2.1 ALP 0100-0115 Magnetic coupling - Maintenance kit........68 12.2.2 ALP 0165-0280 Magnetic coupling - Maintenance kit .......69 12.3 Tensioning element....................70 12.4 Valve body (cone)....................70 12.5 Cylindrical spring..................... 70 12.6 Containment can..................... 70 12.7 Screw plug for ALP magnetic coupling..............71 13 Appendix ........................73 13.1 General drawings ....................

  • Page 7: Warning Signs In Text

    1 Warning signs in text 1.1 Warning signs Pay attention to the safety instructions in this manual. Below are definitions of the three grades of warning signs used in the text where there is a risk for injury to personnel. DANGER DANGER Indicates an imminently hazardous situation which, if not avoided, will result in...
  • Page 8 1 Warning signs in text 200007725-1-EN-GB...

  • Page 9: About This Document

    2 About this document 2.1 General information The operating instructions form part of the pump or of the pump unit and must be kept for future reference. Further more please observe the associated documents. 2.2 Target groups Target group Tasks •...
  • Page 10 2 About this document 200007725-1-EN-GB...

  • Page 11: Safety

    3 Safety 3.1 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 performance limitations specified on the rating plate and in the "Technical data" section. In the case of operating data that does not agree with the specifications on the rating plate, please contact the manufacturer.

  • Page 12: Safety Information

    3 Safety 3.2 Safety information NOTE The following general safety instructions must be observed. • No liability is accepted for damage arising through non-observance of the operating instructions. • Read the operating instructions carefully and observe them. • The operator-owner is responsible for the observance of the operating instructions.

  • Page 13: Safety Instructions For Magnetic Coupling Systems

    Safety 3 3.3 Safety instructions for magnetic coupling systems. Magnetic fields from magnetic coupling systems (MCS) can influence the function and operational safety of electrical and electronic devices. NOTE The following safety instructions must be observed. Additional safety instructions for magnetic coupling systems. •...
  • Page 14 3 Safety 200007725-1-EN-GB...

  • Page 15: Labelling

    4 Labelling 4.1 Type code 1. Model 2. Size 3. Seal type 4. Overflow valve 5. Completion 6. Motor size Figure 1: Type code Table 1: Type code description Pos. Designation Type Model Single pump. Size Corresponds to flow rate in [l/min] at 1 450 min Mechanical seal of hard material.

  • Page 16: Communication Plate

    4 Labelling 4.2 Communication plate 1. Pump type 2. Serial number 3. Year of contructions 4. Item number 5. Temperature max. 6. Differential pressure max. Figure 2: Rating plate 200007725-1-EN-GB...

  • Page 17: Technical Data

    5 Technical data 5.1 Operating limits Table 2: Operating limits Size 100 - 280 Overflow valve A Overflow valve B Differential pressure max. [bar] End pressure max. [bar] Valve opening pressure [bar] 6 ± 10 % 10 ± 10 % Temperature max.

  • Page 18: Required Npsh Values

    NPSH value [mWC] @ NPSH value [mWC] @ Viscosity Viscosity Rotation speed [min Rotation speed [min Size Size 1450 1750 2900 3500 1450 1750 2900 3500 ALP 100 ALP 215 ALP 115 ALP 230 ALP 165 ALP 280 11.4 200007725-1-EN-GB...

  • Page 19: Weights

    Technical data 5 5.3 Weights Table 4: ALP weights, with magnetic coupling Weights (kg) Note Pump Motor Pump size Coupling bracket Pump Bracket Total size foot weight 29.7 ALP–0100 30 Nm 23.0 30.8 29.7 ALP–0115 30 Nm 23.0 30.8 47.4 60 Nm 38.3 10.2...

  • Page 20: Dimensions

    5 Technical data 5.4 Dimensions Table 5: Dimensions ALP pump Size Pump [mm] Shaft end [mm] g1/g2 100–115 272.5 165–215 333.5 122.5 230–280 63.5 178.5 363.5 Table 6: Dimension pump unit with magnetic coupling Pump unit [mm] Magnet power Size Motor size [Nm] LG**...
  • Page 21 Technical data 5 200007725-1-EN-GB...

  • Page 22: Capacity Tables

    Delivery rate [l/min] at viscosity [mm Size [kW] 460** 700** 1200** [min 3400 214.8 219.0 220.3 221.8 223.3 224.6 225.8 226.0 226.5 226.9 ALP 100 1700 1220 100.6 104.8 106.1 107.6 109.1 110.4 111.6 111.8 112.3 112.7 1100 2080 60.3 64.5 65.8 67.3...

  • Page 23: Noise Levels

    Technical data 5 5.6 Noise levels Guide values at 1 m distance, 1 450 min , 8 bar. Table 9: Noise levels Sound pressure level max. ± 3 [dB(A)] Size 100 - 115 165 - 215 230 - 280 Pump 5.7 Overflow valve Table 10: Short-circuit pressure of the overflow valve Short-circuit pressure [bar] at rotation speed [min...
  • Page 24 5 Technical data 200007725-1-EN-GB...

  • Page 25: Function Description

    6 Function description 6.1 Structure Figure 3: Structure of ALP pump Figure 4: Structure of ALP pump with magnetic coupling and motor 1. Overflow valve 5. Balancing cylinder 9. Pump 13. Coupling hub 2. Screw plug 6. Ball bearing 10. Pump bracket 14.

  • Page 26: Standard Direction Of Rotation

    6 Function description 6.1.1 Standard direction of rotation Clockwise, as seen from the drive; marked on the housing by two arrows. Refer to . 6.1.2 Flow direction Marked on the housing by two arrows. Refer to . 6.2 Magnetic coupling The shaft end of the pump is enclosed by a containment can, that is connected air-tight with the motor-side flange of the pump.

  • Page 27: Transportation, Storage And Disposal

    7 Transportation, Storage and Disposal 7.1 Unpacking and checking the state of delivery 1. Upon delivery unpack the pump/pump unit and check for transport damage. 2. Report any transport damage immediately to the manufacturer. 3. Dispose of packing materials in accordance with the locally applicable regulations.

  • Page 28: Storage

    7 Transportation, Storage and Disposal Attach the hoisting equipment to the pump unit, and lift the pump unit. 7.3 Storage During the test run, the internal components of the pump are wetted with test oil, which has a preservative effect. The pipe connections are fitted with protective covers.

  • Page 29: Preservation

    Transportation, Storage and Disposal 7 7.4 Preservation Preservation has to be carried out in the following cases: • For standard delivery : for storage periods exceeding six weeks and in case of adverse storage conditions such as high humidity, salty air,etc. •...

  • Page 30: Removing The Preservation

    7 Transportation, Storage and Disposal 7.4.1 Removing the preservation Recommendations: • Solvent • Steam-jet cleaning device with wax-dissolving additives WARNING Risk of injury through emitted preservative oil. • Wear protective clothing during all the work. • Remove the blind flange with caution to relieve any pressure inside the pump.

  • Page 31: Disposing Of The Pump

    Transportation, Storage and Disposal 7 7.4.2 Disposing of the pump Recommendations: • Solvents or industrial cleaners suitable for the pumped liquid. WARNING Danger of poisoning and damage to the environment from the pumped liquid. • Wear protective clothing during all the work. •...
  • Page 32 7 Transportation, Storage and Disposal 200007725-1-EN-GB...

  • Page 33: Installation, Removal And Connection

    8 Installation, removal and connection 8.1 Safety instruction on installation, removal and connection NOTE The following safety instruction must be observed during installation, removal and connection work. • There is a risk of death for people with pacemakers • Under no circumstances may persons with pacemakers perform installation, removal or connection work.

  • Page 34: Installing The Pump

    8 Installation, removal and connection 8.3 Installing the pump Screw pumps can be operated in any installation position. However, we recommend that the pump should not be mounted above the motor since pumped liquid could enter the motor should a leak occur. Figure 7: Model ALP Horizontal mounting Figure 6: Model ALP vertical mounting Prerequisite:...

  • Page 35: Protect The Pump Against Soiling

    Installation, removal and connection 8 8.4 Protect the pump against soiling CAUTION Damage through impurities in the pipe system. • During welding work attach protective covers to the connecting flanges. • Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and the pump.

  • Page 36: Connecting The Motor

    8 Installation, removal and connection 1. Turn the pump shaft or the fan impeller of the motor. This tests that the pump runs smoothly. If the pump cannot be turned by hand, remedy the fault before installing the pump. 2. During welding work attach protective covers to the connecting flanges. 3.

  • Page 37: Removing The Pump

    Installation, removal and connection 8 8.5 Removing the pump Recommendations: • Vessels for leaking pumped liquid DANGER Risk of death resulting from electric shock. • Ensure that the power supply is disconnected. • The motor may only be separated from the power supply by an authorized electrician.
  • Page 38 8 Installation, removal and connection 200007725-1-EN-GB...

  • Page 39: Operation

    9 Operation 9.1 Commissioning CAUTION 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. CAUTION The following instructions must always be observed. The pump may only be commissioned by authorized qualified personnel.

  • Page 40: Cleaning The Pipe System

    9 Operation 9.2 Cleaning the pipe system To protect the pump against soiling the complete pipe system has to be cleaned carefully before initial commissioning of the pump. If the pipe system is to be rinsed using the pump, an additional commissioning filter has to be installed before the pump.

  • Page 41: Filling The Pump

    Operation 9 9.3 Filling the pump There are two possible ways to fill the pump: 1. Pumped liquid already exists at the suction or pressure side: filling via suction or pressure connection. Figure 10: Filling the pump 2. There is no pumped liquid at the suction or pressure side: filling via the vent hole.

  • Page 42: Filling The Pump Via The Suction Or Pressure Connection

    9 Operation 9.4 Filling the pump via the suction or pressure connection WARNING Danger of injury or poisoning through dangerous pumped liquids. Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible manner. Open the vent hole 3 so that the air can escape during the filling process.

  • Page 43: Checking Direction Of Rotation

    Operation 9 9.5 Checking direction of rotation The direction of rotation and the flow direction are indicated by arrows on the pump. The direction of rotation of the motor gives the direction of rotation of the pump. That is to say, the fan impeller of the motor must rotate in the direction in which the arrow on the pump is pointing to indicate direction of rotation.

  • Page 44: Commissioning The Pump

    9 Operation 9.6 Commissioning the pump Prerequisites: • Pump set up and mounted correctly. • Motor connected correctly. • Pipe system is free of contamination. • Commissioning filter mounted, if the pipe system is to be cleaned with the pump. •...

  • Page 45: Taking Pump Out Of Operation

    Operation 9 9.7 Taking pump out of 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. •...

  • Page 46: Recommissioning The Pump

    9 Operation 9.8 Recommissioning the pump Carry out all the steps as for the commissioning process. Refer to Commissioning on page 39. 200007725-1-EN-GB...

  • Page 47: Maintenance

    10 Maintenance 10.1 Safety instructions on maintenance and repairs DANGER There is a risk of death for people with pacemakers. The following safety instructions must be observed during all work: • Under no circumstances may persons with pacemakers perform maintenance or repair work. •...

  • Page 48: Required Maintenance

    10 Maintenance 10.2 Required maintenance The service life of the pump depends to a great extent on the operating conditions. If the operating limits are observed, refer to Technical data on page 17;the pump has a service life of many years. Signs of progressive wear of individual pump elements: Table 15: Check table for required maintenance Finding...

  • Page 49: Replacing The Magnetic Coupling

    Maintenance 10 10.5 Replacing the magnetic coupling Removing the magnetic coupling 10.5.1 Dismantling the outer rotor Figure 12: Outer rotor disman- tling Ref. Description Ref. Description Ref. Description Pump Outer rotor 914.3 Socket screw Coupling hub Motor 914.5 Socket screw Pump bracket Threaded pin Mounting lever...
  • Page 50 10 Maintenance Before dismantling close the suction and pressure connection of the pump with protective covers . Loosen the connecting screws 914.3 between the motor 529 and pump bracket 180 and lift the pump with pump bracket from the motor. Loosen the threaded pin 884.
  • Page 51 Maintenance 10 Loosen the socket screws 914.5 between the coupling hub 053 and the outer rotor 515 . 200007725-1-EN-GB...

  • Page 52: Dismantling The Inner Rotor

    10 Maintenance 10.5.2 Dismantling the inner rotor Figure 13: Inner motor dismantling Ref. Description Ref. Description Ref. Description Containment can Inner rotor Anti-rotation screw Centring flange 914.2 Socket screw Allen key Pump bracket 914.6 Socket screw Recommendations: • Anti-rotation screw •...
  • Page 53 Maintenance 10 Loosen the socket screws 914.6 between the centring flange 110 and pump. Remove the containment can. To replace the inner rotor 518, insert two anti- rotation screws B into the empty threaded holes of the tensioning element to prevent rotation.

  • Page 54: Installing The Magnetic Coupling

    10 Maintenance 10.6 Installing the magnetic coupling 10.6.1 Mounting the inner rotor Figure 14: Sectional view magnetic coupling Ref. Description Ref. Description Ref. Description Containment can Inner rotor 914.2 Socket screws Distance sleeve Tensioning element 914.6 Socket screws Pump bracket 739.2 O-ring 200007725-1-EN-GB...
  • Page 55 Maintenance 10 Carefully clean the sealing surfaces. Clean and slightly grease the O-ring. Insert the O- ring 739.2 and slide the distance sleeve 040 onto the pump shaft. Clean the contact surfaces of the inner rotor 518 carefully. Oil the tensioning element 585 slightly.
  • Page 56 10 Maintenance Check the position of the tensioning element: the tensioning element has to lie on the distance sleeve and inner rotor. Otherwise loosen the screws again and re- align the tensioning element. If the position is correct, first tighten the screws of the tensioning element with half the tightening torque crosswise.
  • Page 57 Maintenance 10 Place the pump bracket 180 on the pump and tighten the socket screws 914.2 . 200007725-1-EN-GB...

  • Page 58: Mounting The Outer Rotor

    10 Maintenance 10.6.2 Mounting the outer rotor Figure 15: Ref. Description Ref. Description Ref. Description Pump Outer rotor 914.5 Socket screw Coupling hub Motor 914.3 Socket screw Pump bracket Threaded pin Carefully clean the outer rotor 515 with compressed air. Tighten the connecting screws 914.5 of the outer rotor and coupling hub 053 with torque.
  • Page 59 Maintenance 10 The shaft end of the motor must be flush with the front surface of the coupling hub. Place the pump with pump bracket on the motor. Do not use force and ensure that the outer rotor does not strike the containment can. Tighten the connecting screws 914.3 of the motor and pump bracket.

  • Page 60: Replacing The Ball Bearing

    10 Maintenance 10.7 Replacing the ball bearing 10.7.1 Removing the ball bearing Figure 16: Ref. Description Ref. Description Ref. Description 056(*) Supporting ring Circlip Disassembly tool 165.1 Screw plug Ball bearing Open-end wrench 471.2 Circlip 868* Supporting ring Extractor * Only for sizes 100 - 115. Recommendations: •...
  • Page 61 Maintenance 10 Screw in the disassembly tool A by using the open-end wrench B. The main screw will be pressed out of the pump housing. Remove the main screw from the pump housing. Remove the circlip 471.2 and supporting ring 056.

  • Page 62: Installing The Ball Bearing

    10 Maintenance 10.7.2 Installing the ball bearing Figure 17: Ball bearing installa- tion Ref. Description Ref. Description Supporting ring Circlip 165.1 Screw plug Ball bearing Circlip 868* Supporting ring * Only for sizes 100 - 115. Clean the fitting surfaces and the main screw. Grease the main screw slightly.

  • Page 63: Troubleshooting

    11 Troubleshooting 11.1 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 •...

  • Page 64: Troubleshooting

    11 Troubleshooting 11.2 Troubleshooting Table 16: Fault table Cause Remedy - Check shut-off devices in the suction pipe and open them, Pump suction pipe closed. if necessary. Suction valve or pipe obstructed. - Check the suction valve and pipe for clear passage. - Check suction pipe or shaft seal for leaks.
  • Page 65 Troubleshooting 11 Cause Remedy Advanced wear of rotating pump - Check screw set and housing and replace if necessary. components. - Support the weight of the piping. Pump distorted. - Loosen pipe connections and mount stress-free; refer to Installation on page 33. - Provide a flexible bearing arrangement -or Resonance in the system.
  • Page 66 11 Troubleshooting 200007725-1-EN-GB...

  • Page 67: Spare Parts

    12 Spare Parts 12.1 ALP magnetic coupling spare parts Figure 18: ALP 0100–0280: spare parts general drawing 200007725-1-EN-GB...

  • Page 68: Alp Magnetic Coupling - Maintenance Kit

    12 Spare Parts 12.2 ALP Magnetic coupling - Maintenance kit 12.2.1 ALP 0100-0115 Magnetic coupling - Maintenance kit Figure 19: ALP 0100-0115 Magnetic coupling – Maintenance kit 9014380 83 Table 17: ALP-0100-0115, Magnetic coupling, Size 75, Nm 30, IEC 132 ALP 0100-0115 Magnetic coupling Denomination Qty.

  • Page 69: Alp 0165-0280 Magnetic Coupling - Maintenance Kit

    Spare Parts 12 12.2.2 ALP 0165-0280 Magnetic coupling - Maintenance kit Figure 20: ALP 0165-0280 Magnetic coupling – Maintenance kit 9014380 84 Table 18: 0165-0280, Magnetic coupling, Size 75, Nm 60, IEC 132+160 ALP 0165-0280 Magnetic coupling Denomination Qty. Dimensions Pos.

  • Page 70: Tensioning Element

    12 Spare Parts 12.3 Tensioning element Tensioning element, Pos. 585 Pump type Part no. ALP 0100-0115, 9012876 02 Magnetic coupling, ALP 0165-0280, 9012876 03 Magnetic coupling 12.4 Valve body (cone) Valve body (cone), Pos. 305 Pump type Part no. ALP 0100-0115, 9012877 03 Magnetic coupling ALP 0165-0280,...

  • Page 71: Screw Plug For Alp Magnetic Coupling

    Spare Parts 12 12.7 Screw plug for ALP magnetic coupling Figure 21: Srew plug Table 19: Screw plug for ALP magnetic coupling Pump type ALP Screw plug Part no. Pos. no. DVV 38 9046911 01 165.1 0100 0115 DVV 36 9046911 02 165.2 0165...
  • Page 72 12 Spare Parts 200007725-1-EN-GB...

  • Page 73: Appendix

    13 Appendix 13.1 General drawings Figure 22: ALP 0100–0280 Figure 23: Completion magnetic coupling ALP 0100–0280 200007725-1-EN-GB...

  • Page 74: Parts Table

    13 Appendix 13.2 Parts table Table 20: Parts numbers Pos. no. Denomination Note Pump Containment can Distance sleeve Balancing cylinder Coupling hub Supporting ring End cover Pump housing 165.1 Screw plug 165.2 Screw plug Pump bracket Flat gasket Valve body 471.1 Circlip 471.2...

  • Page 75: Tightening Torques

    Appendix 13 13.3 Tightening torques Table 21: Tightening torques Tightening torque [Nm] for screws with metric threads + head contact surfaces with thread measured in inches + wedge lock wash- Stainless steel screws A2 Screw plugs with elastomer and A4 seal 8.8 + Thread...

  • Page 76: Required Tool For Maintenance Work

    13 Appendix 13.4 Required tool for maintenance work Figure 24: Disassembly tool Table 23: Disassembly tool dimensions Disassembly tool dimensions [mm] Size 100 – 280 G 1/2" 200007725-1-EN-GB...

  • Page 77: Ec Declaration Of Conformity

    14 EC Declaration of conformity 200007725-1-EN-GB...

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