PROCESSTEC ViscoTwin 104 3-A Series Technical Data Manual
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PROCESSTEC ViscoTwin 104 3-A Series Technical Data Manual

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Technical Data and Instruction Manual for
ViscoTwin 104-xx 3-A
For more help visit:
www.viscotwin.us/maintenanceandsupport/
- Torque values on drawing for all screws
- 13 Maintenance movies showing all maintenance steps
- electronic form of this manual
- etc.
PROCESSTEC, Inc. | 345 E Tulare Ave, Unit E | Visalia, CA 93277 | USA
www.processtec.com | info@processtec.com
Phone: +1(559) 429-4227 | Fax +1(559) 429-4228

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Summary of Contents for PROCESSTEC ViscoTwin 104 3-A Series

  • Page 1 - 13 Maintenance movies showing all maintenance steps - electronic form of this manual - etc. PROCESSTEC, Inc. | 345 E Tulare Ave, Unit E | Visalia, CA 93277 | USA www.processtec.com | info@processtec.com Phone: +1(559) 429-4227 | Fax +1(559) 429-4228...

  • Page 2: Table Of Contents

    All rights, also reproduction in the form of extracts thereof reserved. All information is supplied without liability PROCESSTEC, Inc. | 345 E Tulare Ave, Unit E | Visalia, CA 93277 | USA www.processtec.com | info@processtec.com Phone: +1(559) 429-4227 | Fax +1(559) 429-4228...
  • Page 3 Serial no: __________ Configuration: ______________________________________________________________________________________________ Content: Specification Instruction manual Explosion drawings Tightening torques May 15, 2015 Created: PROCESSTEC, Inc. | 345 E Tulare Ave, Unit E | Visalia, CA 93277 | USA www.processtec.com | info@processtec.com Phone: +1(559) 429-4227 | Fax +1(559) 429-4228...
  • Page 4 Specification Designation:ViscoTwin 104-xx 3A Serial no _______ Specification   Customer:   Pump   i dentification   ViscoTwin   1 04-xx3- A   Serialy   # :   Pump   t ype:   EDATA   c omponent-­‐ID:   Configuration:   Pump  ...
  • Page 5 Specification Designation:ViscoTwin 104-__ 3A Serial no _______ Coupling   EDATA4U   c omponent   I D   Brand   /   M odel   Love   J oy   A L110   Hub   t ype   p ump   h ead   28mm  ...
  • Page 6 Manometer   -­‐   Sealing   l iquid   r eservoir   -­‐   Visalia,   C A,   U SA,   M ay   1 5,   2 015   Copyright © PROCESSTEC, Inc., 2015 www.viscotwin.us Saved: 15 May 2015...

  • Page 7: Safety Notes

    Manual ViscoTwin 104-xx 3A Chapter 1 Safety notes Important notes • Read these instructions before assembly and initial operation. • They describe the safe use of the pump in all life cycles. • Heed the safety notes contained without fail •...
  • Page 8 Manual ViscoTwin 104-xx 3A Chapter 1 Further applicable documents Heed the following additional documents: Document Description Data sheet Technical data, performance and operating limitations, service conditions Dimensional drawing Pump dimensions and connections with mounting points Spare parts lists Exploded drawing with spare parts Assembly instructions Special models or incomplete machine ATEX supplementary instructions...
  • Page 9 Manual ViscoTwin 104-xx 3A Chapter 1 Intended Use The machine is intended for commercial use and may only be employed for delivery of the agreed pumping media in accordance with this Operating Manual. The operating points (delivery volume, pressure, rotational speed) mentioned in the pump specification (→...
  • Page 10 Manual ViscoTwin 104-xx 3A Chapter 1 Specific safety notes Provide constructional contact protection for hot and cold parts. Provide appropriate earth in case of a possible electrostatic charge. Danger! Rotating screw spindles in the pump can draw in arms or other parts of the body.

  • Page 11: Construction And General Description

    Manual ViscoTwin 104-xx 3A Chapter 2 Construction and general description ViscoTwin pump construction • only exemplary representation Decisive for the dimension is the (dimensional drawing) • 3-A baseframe according to 3-A requirements as per drawing # Drive Coupling with guard Gear housing Bearing housing Pump casing...
  • Page 12 Manual ViscoTwin 104-xx 3A Chapter 2 General description ViscoTwin Screw pumps are rotating displacement pumps for delivering low to highly viscose media. Pumps for use in the foodstuffs and beverage industry are designed and built to the recommendations of DIN EN 1672-2 ‘Food processing machinery - Basic concepts’. This does not include pipe connections, which require special cleaning procedures.

  • Page 13: Transport, Packaging, Storage

    Manual ViscoTwin 104-xx 3A Chapter 3 Transport, packaging, storage Transport / packaging ViscoTwin pumps are shipped in non-returnable packaging. Any transport damage has to be immediately reported to the transport company after receipt of the consignment. Do not put damaged products into operation Warning! The pump can drop or tilt as a result of improper transport.
  • Page 14 Manual ViscoTwin 104-xx 3A Chapter 3 Storage ViscoTwin pumps are sufficiently preserved under normal environmental conditions. Take the following measures when storing for a longer period; • Protect pump from dust, dirt, water, and other harmful environmental influences. Coat all non-painted surfaces with acid-free and resin-free grease.

  • Page 15: Assembly / Installation

    Manual ViscoTwin 104-xx 3A Chapter 4 Assembly / installation Rotational direction The rotational direction of the drive shaft determines the direction of flow. The rotational direction is stated on the data sheet and on the pump casing / coupling guard. Speed and torque of the pump The permissible speed and the maximum torque on the clutch shaft of the screw pumps are shown in the following table:...
  • Page 16 Manual ViscoTwin 104-xx 3A Chapter 4 4.3.1 Tightening torques for specified components Tightening torques has been specified for certain components as shown in the table below: Designation Screw∅ Tightening torque Fitting screws 2259 of the seal housing 10 Nm Gear case cylinder head screws 2258 20 Nm Gearwheel hub cylinder head screws 2186 8 Nm...
  • Page 17 Manual ViscoTwin 104-xx 3A Chapter 4 Possible damage to property ATTENTION • Do not support pipe lines on the pump! Mount pipe lines as force- and torque-free as possible. • Allow for the permissible forces and torques on the ports (see table below) when connecting the pipe lines.
  • Page 18 Instruct Instruction H Instruction H Instruction Handbook Ec ruction Handbook Eco Twin Handbook Eco Twin co Twin co Twin Manual ViscoTwin 104-xx 3A Chapter 4 Chapter 4 Operation and maintenance space requirements Operation and maintenance space requirements Operation and maintenance space requirements Operation and maintenance space requirements Operation and maintenance space requirements Operation and maintenance space requirements...
  • Page 19 Manual ViscoTwin 104-xx 3A Chapter 4 Driving elements Warning! Driving elements are quickly moving during operation. They can squash hands. Potential consequences: Severe or fatal injuries. • Always cover driving elements with a protective guard. 4.8.1 Coupling elements ViscoTwin screw pump with free shaft (cylinder shaft with shaft key) are connected to the drive through a flexible coupling.
  • Page 20 Manual ViscoTwin 104-xx 3A Chapter 4 4.10 Shaft seals It is of the essence that there is a lubricating and cooling film between the seal faces. Depending on application, there are various methods of ensuring that the appropriate medium is being fed to the seal so that this film can be developed.
  • Page 21 Manual ViscoTwin 104-xx 3A Chapter 4 4.10 Quench media The manufacturer uses only quench fluids suitable for food products (e.g. distilled water). Some usable quench media are being shown below. Change these quench media at regular intervals. Do not use aggressive quench fluids. Glycerine/water mix This mixture is used in different concentrations.

  • Page 22: Commissioning

    Manual ViscoTwin 104-xx 3A Chapter 5 Commissioning Preparing commissioning Warning! Risk of injuries through rotating machine parts or from liquids escaping under high pressure. Potential consequences: Severe or fatal injuries. • Do not perform any work with the pump running! •...
  • Page 23 Manual ViscoTwin 104-xx 3A Chapter 5 5.1.4 Pumps in a processing system by 3A Standard (02-11) Pumps to be used in a processing system not designed so that the system automatically is shut down if the product pressure in the system becomes less than of the atmosphere and cannot be started until the system is resterilzed shall have a steam or other sterilizing medium chamber surrounding (1) the shaft, (2) the portion of the inlet and outlet connection adjacent to the product, and (3) the pump cover.
  • Page 24 Manual ViscoTwin 104-xx 3A Chapter 5 Switching on Check before switching on: Pump with drive safely installed and connected? • Connections sealing and connected stress-free? • • Oil level checked? Quench fluid level OK? Correct pressure set in case of a counter-pressure device? •...

  • Page 25: Placing Out Of Operation

    Manual ViscoTwin 104-xx 3A Chapter 6 Placing out of operation Warning! Rotating machine parts or liquids escaping under high pressure. Potential consequences: Severe or fatal injuries. Shutting off Stop the pump by shutting down and switching off the drive unit. Shut the pressure and suction-side valves.

  • Page 26: Maintenance And Servicing

    Manual ViscoTwin 104-xx 3A Chapter 7 Maintenance and servicing Warning! Risk of injuries through rotating machine parts Potential consequences: Severe or fatal injuries. Maintenance after commissioning All external screw connections of the pump or pump unit should be checked and, if necessary, tightened after approx.
  • Page 27 Manual ViscoTwin 104-xx 3A Chapter 7 Lubrication Pump bearings and gear run in an oil bath. Replacement of these bearings and gear wheels is recommended after 20,000 hours of operation. You should set shorter change intervals for particularly difficult operating conditions, such as: large temperature variations •...
  • Page 28 Manual ViscoTwin 104-xx 3A Chapter 7 Lubricating agents 7.4.1 Gear oil with NSF or USDA H1 approval The following gear oil suitable for food products to the FDA guideline NSF-H1 and viscosity of ISO VG 220 is factory-used in the screw pump for applications in the food sector. Product Gear oil Castrol...
  • Page 29 Manual ViscoTwin 104-xx 3A Chapter 7 Maintenance of shaft seal Check the quench fluid filling level regularly and at least once a week. Top up the quench fluid as required or change the fluid at regular intervals. The filling level can also be monitored using a level indicator.

  • Page 30: Disturbances And Their Elimination

    Manual ViscoTwin 104-xx 3A Chapter 8 Disturbances and their elimination Disturbances on pumps and pump units can basically be of hydrodynamic, mechanical or electrical nature. Mechanical and hydrodynamic disturbances checklist Type of disturbance possible cause Elimination Pump does not start Jam by foreign objects Remove foreign objects Deposits at shutdown...

  • Page 31: Disassembly And Assembly

    Manual ViscoTwin 104-xx 3A Chapter 9 Disassembly and assembly Warning! Risk of injuries through rotating machine parts or from liquids escaping under pressure or hot surfaces. Potential consequences: Severe or fatal injuries. • Do not perform any work with the pump running! •...
  • Page 32 Manual ViscoTwin 104-xx 3A Chapter 9 Disassembling and installing the pump 9.3.1 Driving elements Caution! Risk of jamming and crushing when disassembling the drive. Potential consequences: Minor injuries Fig. 9.1 Disassembly: Loosen screws 2246 using a socket of size 10 mm and remove screws and coupling guard. Disconnect the pump from piping system.
  • Page 33 Manual ViscoTwin 104-xx 3A Chapter 9 9.3.2 Gear housing Fig. 9.2 Disassembly: Remove key 1183. Open the upper locking screw 2233 and then the lower locking screw 2233 in gear housing 2172 and drain the gear oil into a sump tray. Loosen the screws 2258 and remove them together with the washers 2187.
  • Page 34 Manual ViscoTwin 104-xx 3A Chapter 9 9.3.3 Cover Fig. 9.3 Disassembly Loosen and remove screws 1041. Remove the cover. Thoroughly clean the cover and its seal seat. • If necessary, loosen the cover using slight blows of a hammer (plastic hammer) because it is centred by dowel pins 2196.
  • Page 35 Manual ViscoTwin 104-xx 3A Chapter 9 Installation: Installation: Carefully slide the screw spindles (imperative in pairs) onto the shafts. The left-hand spindle will then be located on the driver shaft (long shaft) and the right-hand spindle on the driven shaft. Observe correct seat of the O-rings when sliding the spindle onto the seal. Insert O-ring 2194 into the greased groove of the spindle nuts.
  • Page 36 Manual ViscoTwin 104-xx 3A Chapter 9 9.3.5 Arranging the pump casing There are 3 intended arrangements of the dowel pins corresponding to the three different positions of the pump casing. The arrangement of the different positions is shown in colours here. KddKD KddKD LEFT...
  • Page 37 Instruction H Inst Instruct Instruction H Instruction Handbook Eco T uction Handbook Eco Twin l Handbook Eco Twin l co Twin l co Twin l Manual ViscoTwin 104-xx 3A Chapteter 9 Chap • The pump casing must be clean. The pump casing must be clean. The pump casing must be clean.
  • Page 38 Manual ViscoTwin 104-xx 3A Chapter 9 Shaft seal 9.4.1 Shaft seal (single-acting) Disassembly: Disassemble cover 1012. Disassemble pump housing 1033. Disassemble both screw spindles. Pull down inboard rotor holders 80 from the shaft. Inserted in it are seal face 40, drive pins 210 as well as O-rings 90, 130 and 220.
  • Page 39 Manual ViscoTwin 104-xx 3A Chapter 9 Installation: Insert drive disks 150 with the pre-assembled drive pins 210 (glue them into the disc ring using grease) into the seal housing from behind. The drive pins must be directed to the front Fit backup rings 180 into the rear groove of the seal housing.
  • Page 40 Manual ViscoTwin 104-xx 3A Chapter 9 9.4.2 Shaft seal (single-acting with quench) Disassembly: Drain the quench fluid. Disassemble the auxiliary systems. Disassemble cover 1012. Disassemble pump housing 1033. Disassemble both screw spindles. Pull down inboard rotor holders 80 from the shaft. Inserted in it are seal face 40, drive pins 210 as well as O-ring 90, 130 and 220.
  • Page 41 Manual ViscoTwin 104-xx 3A Chapter 9 Possible damage to property ATTENTION • Equally clean the seal housing as well as the shafts and seal seats and carefully check the removed parts. Replace any damaged parts as well as all O-rings and shaft sealing rings •...
  • Page 42 Manual ViscoTwin 104-xx 3A Chapter 9 Set cover in place with O-ring 2192, screw in screws 1041 and tighten them. (torque 150Nm) Connect quench chamber, fill up fluid and vent the shaft seal. Possible damage to property ATTENTION • Slide the screw spindles together onto the shafts. •...
  • Page 43 Manual ViscoTwin 104-xx 3A Chapter 9 Installation: Fig. 9.6 Unpack new seals and place them onto a clean and soft pad. Grease 4 drive pins 210 and insert them greased into drive disc 150 (2x) these drive pins 210 are inserted paired and that is 2 each on the front side and 2 each on the rear side of drive disc 150.
  • Page 44 Manual ViscoTwin 104-xx 3A Chapter 9 Slide the seal housing to the bearing housing via the shafts and place it in position. Screw in the fitting screws 2259 incl. washers 2260 and little by little tighten evenly. Check on the back gap that the grooves of rotor 20 engaged in nicks of stop ring 60 Possible damage to property ATTENTION •...
  • Page 45 Manual ViscoTwin 104-xx 3A Chapter 9 Possible damage to property ATTENTION • Check the free room of motion of the sealing by pushing the inboard rotor holder and spinning it bidirectional. During spinning a small gap shall be noticeable, coming from the gap between the drive pins 210 and the grooves they are positioned in the seal faces.
  • Page 46 Manual ViscoTwin 104-xx 3A Chapter 9 9.4.4 Bearing Disassembly: • For this purpose, the following pump elements need to be removed before: drive, coupling elements if necessary, gear housing, cover, pump casing, screw spindles, and shaft seal. • Disassembled bearings need to be replaced with new ones during the assembly work.
  • Page 47 Manual ViscoTwin 104-xx 3A Chapter 9 Fig. 9.8 Using a press, press out the shafts incl. bearings and distance rings toward the drive end. Afterwards, remove locking rings 1009 and remove the needle bearings from the shaft using an extractor tool. Next, pull out angular ball bearings 2181 from the shaft one after the other and remove distance rings 1530, 1121 and spacer rings 1529.
  • Page 48 Manual ViscoTwin 104-xx 3A Chapter 9 Possible damage to property ATTENTION • Align the distance bushes and rings precisely when pressing them in otherwise they will be destroyed. Install the driven shaft in similar way. Into the bearing housing new shaft seals 1011 press with a mounting sleeve. (The spiral ring of the sealing lip shows in the pump housing).
  • Page 49 Manual ViscoTwin 104-xx 3A Chapter 9 Adjusting screw spindles. Fig. 9.10 Installation: Insert keys 2179. Slide gear wheel 2183 onto the drive shaft 1000, screw on and tighten shaft nut 1526. (Tightening torque 70 Nm for M35, 90 Nm for M45) (Plug steel mandrel through the shaft hole counter holding with it while tightening the shaft nut).
  • Page 50 Manual ViscoTwin 104-xx 3A Chapter 9 Fig. 9.11 Adjustment: Turn drive shaft 1000 until the spindles stop. Mark this position on gear wheel hub 2176 and driven gear wheel 2184. Now turn the drive shaft into the opposite direction until the spindles jam. Mark this position on gear wheel hub 2176, too.

  • Page 51: Stocking Of Spare Parts

    No liability will be assumed for wrong deliveries on account of insufficient data. Send your spare parts order to the following address, please: PROCESSTEC, Inc. | 345 E Tulare Ave, Unit E | Visalia, CA 93277 | USA Phone: +1(559) 429-4227 | Fax +1(559) 429-4228...

  • Page 54: Appendix

    Instruction Manual ViscoTwin Appendix Appendix - Special wrenches and tools - Explosing drawings with index ViscoTwin 70_IM_May 2015 01/2014 Appendix Page A-3...
  • Page 55 The indicated tools can be found under the designated article number at PROCESSTEC , Inc. , Visalia, CA If you should wish to produce the tools yourself, you can request a list of the tools with the measurements.
  • Page 56 Instruction Manual ViscoTwin Appendix Tool Tool No.: Drawing number Pump model Item Number Material 1011-718 # 070 95578 1.4301 Installation bearing crown shaft 1011-772 # 104 95579 ring gasket 1011-773 # 130 95580 T 11 1011-416 # 070 95553 1.4301 Installation pipe needle roller bearing...
  • Page 57 Instruction Manual ViscoTwin Appendix Tool Tool No.: Drawing number Pump model Item Number Material Shaft ring gasket T 16 1010-806 # 070 95439 1.4301 assembly sleeve T 25 1011-082 # 104 95441 bearing housing T 26 1011-083 # 130 95442 1011-351 # 070 41446...
  • Page 58 Instruction Manual ViscoTwin Appendix Tool Tool No.: Drawing number Pump model Item Number Material T 42 1011-441 #070 95561 1.4301 Installation pipe inner race retaining T 44 1011-444 #104 ring needle roller T 45 1011-445 #130 bearing Sliding sleeve T 43 1011-446 # 070 95562...
  • Page 59 Instruction Manual ViscoTwin Appendix Appendix 2: Explosion drawings with index ViscoTwin 70 (see following pages) ViscoTwin 70_IM_May 2015 01/2014 Appendix Page A-8...
  • Page 61 The Engineering Design and Technical Construction File CIP - SIP and COP Instructions, Swab-Testing Instructions CIP & SIP Instructions Pumps in a processing system by 3A Standard (02-11) Pumps used in a SIP processing system must be equipped with a pressure monitoring device, which shuts down the system immediately if the processed product falls below atmospheric pressure and the system cannot be re- started without getting sterilized again.
  • Page 62 ATTENTION Possible damage to property Avoid abrupt changes in temperature during cleaning process with the pump in stationary state, fill in hot medium and wait until the pump has warmed up.. 4.2 Inspection of sanitary pumps for food processing. The instruction given in chapter 7.2 ‘Notes on service and maintenance’ apply exceedingly to sanitary pumps for food processing.
  • Page 63 Pump with drive safely installed and connected? 4.5.2 Connections sealing and connected stress-free? 4.5.3 Oil level checked? 3   PROCESSTEC, Inc. | 345 E Tulare Ave, Unit E | Visalia, CA 93277 | USA www.processtec.com | info@processtec.com Phone: +1(559) 429-4227 | Fax +1(559) 429-4228...
  • Page 64 Potential consequences: Severe or fatal injuries. Secure the pump through an approved overpressure protection. Possible damage to property ATTENTION 4   3-A Sanitary Standards Certification | Issued: May 2015 | EDTCF- Version 1.0 | Author: Karin Duerig, PROCESSTEC , Inc.
  • Page 65 General recommendation: Please put the recommended maintenance routine of the Manual on page 21 to set up a service-routine for your ViscoTwin. PROCESSTEC, Inc. | 345 E Tulare Ave, Unit E | Visalia, CA 93277 | USA www.processtec.com | info@processtec.com...

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