UNIBLOC -PD 200 Operation & Service Manual
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UNIBLOC -PD 200 Operation & Service Manual

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UNIBLOC-PD
®
Operation & Service Manual
Models: 200-576
Original Instructions
MANUAL NO.: PD200-576 REVISION: 05/2022

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Summary of Contents for UNIBLOC UNIBLOC-PD 200

  • Page 1 UNIBLOC-PD ® Operation & Service Manual Models: 200-576 Original Instructions MANUAL NO.: PD200-576 REVISION: 05/2022...
  • Page 2 Information contained in this manual is subject to change without notice Copyright © 2022 and does not represent a commitment on the part of Unibloc Hygienic Unibloc Hygienic Technologies, LLC Technologies, LLC. No part of this manual may be reproduced or trans- All Rights Reserved.

  • Page 3: Table Of Contents

    4.4.1.3 UNIBLOC 300-575 Single Mechanical Seal Removal ................. 18 4.4.1.4 UNIBLOC 300-575 Single Mechanical Seal Installation ................18 4.4.1.5 UNIBLOC 501, 551, 576 Front Loaded Single Mechanical Seal Removal ..........19 4.4.1.6 UNIBLOC 501, 551, 576 Front Loaded Single Mechanical Seal Installation ..........19 4.4.1.6 UNIBLOC 500, 550, 575 Front Loaded Single Mechanical Seal Removal ..........
  • Page 4 4.4.6.3 UNIBLOC 300 Series Front Loaded Double O-Ring™ Seal Removal ............28 4.4.6.4 UNIBLOC 300 Series Front Loaded Double O-Ring™ Seal Installation ........... 28 4.4.7 UNIBLOC 200-575 Seal Installation – Final Steps ................29 4.4.7.1 Rotor Housing Installation ........................... 29 4.4.7.2 Rotor Installation ............................

  • Page 5: Pump Identification

    Stainless Pump Bearing Housing Standard Front Cover 316 Stainless Rotor Housing 1.5” T/C, Horizontal Mounting Class C 316L Stainless Rotors Standard Shafts, Drive Shaft in Top Position Single Mechanical Shaft Seal (SiC vs SiC) EPDM Elastomers UNIBLOC-PD Operation & Service Manual: PD200-576 5...

  • Page 6: General

    Amendment: CR NO 10/2011: Plastic materials and articles in contact with food A technical construction file for this machinery is retained at the above address. Signed: Date: January 12, 2021 Bhavesh Patel, Operations Manager Q42.2101.1 6 UNIBLOC-PD Operation & Service Manual: PD200-576...

  • Page 7: General Description

    1.2 General Description UNIBLOC-PD is a positive displacement rotary lobe pump. It may be supplied with a drive unit (figure 1.0-1.2) or without a drive unit (figure 1.3). When supplied with a drive unit it is called UNIBLOC-PD ASSEMBLY. Figure 1.0 indicates various parts of an assembly.

  • Page 8: Limitation

    1.2.4 Marking – Standard Standard marking is machined on the side of pumps’ bearing housing. Figure 1.3 See figure 1.4 for details. Pump size is machined on rotor housing next to the ports.   Figure 1.4 8 UNIBLOC-PD Operation & Service Manual: PD200-576...

  • Page 9: Safety

    Do not exceed the pump’s maximum operating pressure, speed or temperature. Do not modify the operating parameters/ system for which the unit was originally supplied for without first consulting your local supplier.   Pump installation and operation must always comply with prevailing health and safety regulations. UNIBLOC-PD Operation & Service Manual: PD200-576 9...
  • Page 10 If an integrated safety relief valve is installed, do not allow extended periods of recirculation through the valve. UNIBLOC-PUMP can either integrate a safety valve with the front cover, or supply one as a separate unit. Please contact your supplier.

  • Page 11: Installation

    Selecting a clean, dry storage location free from vibration. In a moist or dusty atmosphere, further protect the pump/as- sembly with suitable cover. • Rotating the pump or pump assembly by hand every week, to prevent bearing damage. UNIBLOC-PD Operation & Service Manual: PD200-576 11...

  • Page 12: System Design

    Double mechanical flushed seal pressure: 1bar (15psi) higher than the discharge pressure of the pump ATTENTION Single mechanical with flushed housing max pressure: 0.5bar (7psi) Minimum flow rate required per seal: 1lpm (0.3gpm) or a rate that keeps seal temperature within 5°C (9°F) 12 UNIBLOC-PD Operation & Service Manual: PD200-576...
  • Page 13 (i.e diaphragm valve) OUTLET PRESSURE CONTROL VALVE GAUGE (i.e diaphragm valve) PRESSURE GAUGE CHECK VALVE SHUT OFF VALVE CHECK VALVE FLUSH SHUT OFF INLET VALVE FLUSH INLET   ALTERNATE PIPING ARRANGEMENTS Figure 3.3.2 UNIBLOC-PD Operation & Service Manual: PD200-576 13...

  • Page 14: Double O-Ring & O-Lip Seal Flushing/Cooling

    In this case, the seal flush chambers are filled through grease nipples with approved grease that is suitable for use with the pumped media. Unibloc recommends using Lubri- plate Synxtreme FG-2 calcium sulfonate complex grease.

  • Page 15: Maintenance

    Always use rubber gloves and protective goggles if handling caustic substances. The rotors and shaft seals in the pump have been selected for specific temperature and pressure conditions. Ver- ATTENTION ify with UNIBLOC-PUMP or the documentation supplied with the pump that the operating parameters are not exceeded. ATTENTION Always rinse well with clean water after using cleaning agent.

  • Page 16: Maintenance Schedule And Recommended Spare Parts

    When applications exceed constant service temperatures of 180º C (356º F) a vent and high temperature lubricant must be used. For such cases, contact UNIBLOC-PUMP or your supplier for an adequate service schedule.

  • Page 17: Single Mechanical Seal

    These can be replaced with other materials upon request. UNIBLOC-PD 501 Series has front loaded seals. This seal comes with different seal face combinations. (See drawing G812B for details.) Maximum shaft rotational speed for this seal is 2.4 m/s (7.8 ft/s) or 800rpm and the maximum service pressure should not exceed 15 bar (220 psig).

  • Page 18: Unibloc 300-575 Single Mechanical Seal Removal

    Seal Faces so that their lapped sealing surfaces do not get scratched. If not being replaced, the Drive Collars may remain on the shafts, otherwise loosen the set screws and slide them off the shafts. UNIBLOC-PD 500 Series may use wear sleeves. See section 4.4.4.1 sketch.

  • Page 19: Unibloc 501, 551, 576 Front Loaded Single Mechanical Seal Removal

    4.4.1.5 UNIBLOC 501, 551, 576 Front Loaded Single Mechanical Seal Removal Remove the Shaft O-rings (item 27 in Figure 4.4.1) located behind the shaft splines. Use two long flat head screwdrivers 180º apart to pry the Shaft Sleeve out of the Rotor Housing. Use razor blade or sharp flat head screwdriver to remove the Rotating Seal Face from the Shaft Sleeve.

  • Page 20: Unibloc 500, 550, 575 Front Loaded Single Mechanical Seal Removal

    4.4.1.6 UNIBLOC 500, 550, 575 Front Loaded Single Mechanical Seal Removal Remove the Shaft O-rings (item 27 in Figure 4.4.1) located behind the shaft splines. Use two long flat head screwdrivers 180º apart to pry the Shaft Sleeve out of the Rotor Housing. Use razor blade or sharp flat head screwdriver to remove the Rotating Seal Face from the Shaft Sleeve.

  • Page 21: Flushed Single Mechanical Seal

    4.4.1. The drive collar is different, however. The flushed single mechanical is not available   for UNIBLOC 200-0, 200, 250, and 275. See section 3.3 for more information about flushing systems. 4.4.2.1 Flushed Single Mechanical Seal Removal Disconnect the flush tubing from the flush housings (55).

  • Page 22: Double Mechanical Seal

    (primary & secondary) as the Single Mechanical Seals discussed in section 2.1.2. The Drive Collar and Rotating Seal Face are different, however. The flushed Double Mechanical Seal is not available for UNIBLOC 200-0, 200, 250, and 275. See section 3.3 for more information about flushing systems.

  • Page 23: Double Mechanical Seal Installation

    10 bar (150 psig). The seal does not require external lubrication and can be run dry for short periods. It is available for all models except UNIBLOC 200-0, 200, 250, and 275 which has the two lips only and not the two shaft o-rings.

  • Page 24: Unibloc 200-575 Double O-Lip™ Seal Removal

    4.4.4.1 UNIBLOC 200-575 Double O-Lip™ Seal Removal Loosen the stud nuts (item 43 in Figure 4.4.1). Remove the rotor housing (item 1 in Figure 4.4.1) by pulling on the ports or by tapping gently with a rubber mallet. The entire seal with all components will come off attached to the rotor housing. Remove the Bolts and Seal Retaining Rings.

  • Page 25: Single O-Ring Seal

    (115 psig). The o-ring seal must never be allowed to run dry as they will be damaged. This seal uses the pumped product as a lubricant. 4.4.5.1 UNIBLOC 200-275 Single O-Ring Seal Removal Loosen and remove the acorn nuts from the Rotor Housing. Loosen the Threaded Studs by locking two M6 nuts against each other on the exposed threaded stud ends.

  • Page 26: Unibloc 300-575 Single O-Ring Seal Removal

    4.4.5.3 UNIBLOC 300-575 Single O-Ring Seal Removal Loosen and remove the bolts from the Threaded Studs. Remove the Rotor Housing by pulling on the ports or by tapping gen- tly with a rubber mallet. All seal parts will come off with the housing. Remove the Seal Retainer Rings by unscrewing the Bolts.

  • Page 27: Double O-Ring Seal

    See section 4.4.7 for completing the installation. It is imperative that the cavity between the o-rings is filled with grease or the flushing system is reconnected before operation is resumed. UNIBLOC-PD Operation & Service Manual: PD200-576 27...

  • Page 28: Unibloc 300 Series Front Loaded Double O-Ring™ Seal Removal

    4.4.6.3 UNIBLOC 300 Series Front Loaded Double O-Ring™ Seal Removal If the rotors were removed, the rotor housing does not need to be taken off. The Double O-Ring Seal Cartridge can be removed by placing screwdrivers between the rotor housing and gearbox and pushing them out.

  • Page 29: Unibloc 200-575 Seal Installation - Final Steps

    (20). Make sure the alignment mark on the rotor housing lines up with the one on the bearing housing (6). The rotor hous- ing must make firm contact with the bearing housing. On UNIBLOC models 300-575, fasten the hex nuts (43) with the split washer (44) on the stud ends and tighten in a cross pattern.

  • Page 30: Unibloc 501 Series Seal Installation - Final Step

    2000 hours of service, whichever occurs first. When applications exceed constant service temper- atures of 1800C (3560F) a vent and high temperature lubricant must be used. For such cases, contact UNIBLOC-PUMP or an authorized service center for an adequate service schedule.

  • Page 31: Bearing Housing Disassembly

    Insert the housing studs (15) and secure them with the split washers (44) and hex nuts (43). The UNIBLOC 200, 250, and 275 have one piece studs (15) and do not use items (43) and (44). To tighten these studs lock two M6 nuts against each other on the stud end.

  • Page 32: Pump Assembly - Stainless Steel Rotors - Final Step

    Stand the pump on the splined ends and fill the bearing housing cavity with approved oil listed in section 5.2. Place the oil seal(s) (24; 24 & 45 for UNIBLOC 200-275) in the bearing housing cover, text side out. Place the o-ring (25) into the groove on the rear side of the bearing housing.
  • Page 33 The Front Cover Wear Rings may be removed from the Front Cover by gently pulling them from the spigots. Once removed, be sure to store wear rings in a safe place. FOODFIRST FRONT COVER (HP) SPIGOTS FRONT COVER WEAR RINGS fig. 4.5.5 UNIBLOC-PD Operation & Service Manual: PD200-576 33...
  • Page 34 DOWEL PIN HOLES FRONT COVER WEAR RINGS fig. 4.5.8 34 UNIBLOC-PD Operation & Service Manual: PD200-576...

  • Page 35: Relief Valve Cover Service

    (15) so that it returns to the mark and thread   on the adjusting sleeve (16) tight against it. Replace the housing (10) and tighten. The pump may now be returned to service. UNIBLOC-PD Operation & Service Manual: PD200-576 35...

  • Page 36: Relief Cover Model #B

    Thread the spring adjuster back into the spring housing and tighten. The pump may now be returned to service. Rotor Housing Cover Studs Diaphragm - PTFE Diaphragm - Viton Spring Housing Spring Plunger Washer Lock Ring Dome Nuts Spring Adjuster 36 UNIBLOC-PD Operation & Service Manual: PD200-576...

  • Page 37: Compac Pump Series Service

    Once pump is decoupled from the electric or gear motor, the Direct flange (for Compac Direct) or Flex flange (for Compac Flex) will act as the rear cover referenced in earlier sections of the Service Manual. Decoupling Compac Direct Decoupling Compac Flex UNIBLOC-PD Operation & Service Manual: PD200-576 37...

  • Page 38: Troubleshooting

    Replace bearings. Gears worn. Replace gears. Foreign particles in pump. Install suction side filter. Particles in product too large. Increase rotor clearances. Use plastic rotors. Increase pump size. Discharge pressure too high. See B-4. 38 UNIBLOC-PD Operation & Service Manual: PD200-576...
  • Page 39 Can come in contact with seals. out flushing liquid. Replace worn seal parts. Seal incompatible with liquid Contact factory for proper seal selection, operation, and replace if necessary. UNIBLOC-PD Operation & Service Manual: PD200-576 39...

  • Page 40: Technical Data

    Drawing D100 shows overall dimensions for all models, 200-0 to 677. A separate service manual is required for model 600-677. 501 Series pumps are not shown in general dimensions below. UNIBLOC PUMP ® 40 UNIBLOC-PD Operation & Service Manual: PD200-576...

  • Page 41: Lubricants And Bearing Housing Oil Specification

    5.2 Lubricants and Bearing housing Oil Specification The UNIBLOC-PD pumps are factory shipped with synthetic oil from Royal Purples: Poly-Guard® FDA. The oil is FDA, OSHA and CFR compliant. Before checking the oil levels DISENGAGE THE POWER SUPPLY TO THE MOTOR.

  • Page 42: Tools And Torque Requirements

    Table 5.3.1 5.3.1 Special Tools There are only a few special tools needed to assemble the UNIBLOC in a safe and secure way. Please contact your pump supplier for ordering. 1) Bearing housing series 200 (Model 200-0 to 275) requires a socket removal/installation tool. Part# 6006-2 2) A plastic spline assembly sleeve is highly recommended when installing the rotor housing.

  • Page 43: Rotor Clearances

    30 (11.8) 28 (11.0) 28 (11.0) 34 (13.4) 25 (9.8) 30 (11.8) 30 (11.8) 28 (11.0) 28 (11.0) 34 (13.4) 25 (9.8) 30 (11.8) 30 (11.8) 28 (11.0) 30 (11.8) 35 (13.8) 25 (9.8) 30 (11.8) UNIBLOC-PD Operation & Service Manual: PD200-576 43...

  • Page 44: Foodfirst Wear Ring Ranges

    DIMENSION PUMP SIZE ACCEPTABLE RANGE DISCARD & REPLACE 300, 350 0.09mm to 0.07mm LESS THAN 0.07mm 400, 450 0.07mm to 0.05mm LESS THAN 0.05mm 500, 550, 575 0.15mm to 0.13mm LESS THAN 0.13mm 44 UNIBLOC-PD Operation & Service Manual: PD200-576...

  • Page 45: Spare Parts

    6.0 Spare Parts UNIBLOC-PD Operation & Service Manual: PD200-576 45...
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  • Page 70 Unibloc to arrange return of the faulty product, shipping prepaid and fully insured, to an authorized Unibloc service facility. If upon inspection of the item in question, defects in workmanship or materials are revealed, Unibloc’s sole obligation under this...

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