Alfa Laval SX Instruction Manual
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Alfa Laval SX Instruction Manual

Alfa Laval SX Instruction Manual

Rotary lobe pumps
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Alfa Laval SX
Rotary lobe pumps
3202-0011
Instruction Manual
Lit. Code
200007900-4-EN-GB
BRITISH ENGLISH

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  • Page 1 Alfa Laval SX Rotary lobe pumps 3202-0011 Instruction Manual Lit. Code 200007900-4-EN-GB BRITISH ENGLISH...
  • Page 2 © Alfa Laval AB 2024-10 This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval AB (publ) or any of its affiliates (jointly “Alfa Laval”). 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’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 Declarations of Conformity .................5 EU Declaration of Conformity..................5 UK Declaration of Conformity..................6 2 Safety ..........................7 Safety Signs......................8 Safety precautions....................10 Warning Signs in Text....................14 Requirements of Personnel..................15 Recycling Information....................16 3 Introduction .........................17 General Information....................17 4 Installation ........................
  • Page 4 Weight........................52 Tool Requirements....................53 Pump Data Table.....................54 Pumphead Clearance Information................55 7 Spare Parts .........................57 Ordering Spare Parts....................57 Alfa Laval Service....................57 Warranty - Definition....................58 8 Parts Lists and Exploded Views ..............59 SX1-3 Pump Range....................59 SX4 Pump Range....................61 SX5 Pump Range....................63...

  • Page 5: Declarations Of Conformity

    1 Declarations of Conformity 1.1 EU Declaration of Conformity The designated company Alfa Laval Kolding A/S, Albuen 31, DK-6000 Kolding, Denmark, +45 79 32 22 00 Company name, address and phone number Hereby declare that Pump Designation SX1, SX2, SX3, SX4, SX5, SX6, SX7 Type Serial number from E10.000 to E1.000.000...

  • Page 6: Declaration Of Conformity

    1 Declarations of Conformity 1.2 UK Declaration of Conformity The designated company Alfa Laval Kolding A/S, Albuen 31, DK-6000 Kolding, Denmark, +45 79 32 22 00 Company name, address and phone number Hereby declare that Pump Designation SX1, SX2, SX3, SX4, SX5, SX6, SX7 Type Serial number from E10.000 to E1.000.000...

  • Page 7: Safety

    Instruction Manual without prior notice or any obligation. The English version of the Instruction Manual is the original manual. Alfa Laval cannot be held responsible for incorrect translations. In case of doubt, the English version applies.

  • Page 8: Safety Signs

    2 Safety 2.1 Safety Signs Mandatory Action Signs General mandatory action sign. Refer to instruction manual. Use eye protection - safety glasses. Use protective hand wear - safety gloves. Wear protective equipment - safety helmet. Use ear protection in noisy environments - noise protector. Wear protective equipment - safety shoes.
  • Page 9 Safety 2 Transportation with forklift truck or other industrial vehicles if heavy. Electricity. Sharp element. Crushing of hands. 200007900-4-EN-GB...

  • Page 10: Safety Precautions

    Always ensure that compressed air is released. Always transport the pump in its upright position. Always use predesigned lifting points if defined. Ensure that the lifting equipment is suitable for the supplied Alfa Laval product. Always ensure that the unit is securely fixed during transporta- tion.

  • Page 11: Operation

    Necessary precautions must be taken if leakage occurs as this can lead to hazardous situations. Always handle lye and acid with great care. Never use the pump for products not mentioned in the Alfa Laval pump selection program. Always follow the instructions in the safety data sheets from the suppliers of cleaning agents, detergents, oils etc.
  • Page 12 2 Safety Maintenance In order to optimise the operation of the supplied Alfa Laval prod- uct and to minimize the down time due repair activities, the main- tenance should consist of: • Inspection and maintenance of the supplied Alfa Laval prod- uct: strictly follow the technical documentation •...
  • Page 13 Safety check A visual inspection of any protective device (shield, guard, cover or other) on the supplied Alfa Laval product shall be carried out at least every 12 months. If the protective device is lost or damaged, especially when this leads to deterioration of safety performance, it shall be replaced.

  • Page 14: Warning Signs In Text

    Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate damage to the supplied Alfa Laval product. NOTE Indicates important information to simplify or clarify procedures. 200007900-4-EN-GB...

  • Page 15: Requirements Of Personnel

    Trainees can perform tasks under the supervision of an experienced employee. People in general The public shall not have access to the supplied Alfa Laval product. In some cases, specially skilled personnel may need to be hired (i.e. electricians, welders). In some cases the personnel has to be certified according to local regulations with experience of similar types of work.

  • Page 16: Recycling Information

    Metal straps should be sent for material recycling Maintenance During maintenance, oil (if used) and wear parts in the supplied Alfa Laval product should be replaced. • Oil and all non-metal wear parts must be disposed of in accordance with local regulations •...

  • Page 17: Introduction

    Cleaning-in-Place (CIP) and Sterilization- in-Place (SIP). 3.1 General Information The SX pump is a positive displacement rotary lobe pump; it may be supplied with or without a drive unit (see drawing). The drawing shown indicates various parts of the pump unit.
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  • Page 19: Installation

    4 Installation 4.1 Unpacking, Handling and Storage NOTE Refer to the pump weights guide (See Weight on page 52) before selecting and using any lifting gear. The drawing show how the pump should be lifted. Ensure that lifting equipment is correctly rated and used within these limits.

  • Page 20: System Design And Installation

    4 Installation 4.2 System Design and Installation NOTE To ensure optimum operation it is important that any pump unit is installed correctly. When designing a pumping system the following should be taken into consideration. 4.2.1 System Design Discharge line • Confirm the Net Positive Suction Head (NPSH) available from the system exceeds the NPSH re- quired by the pump, as this is crucial for ensuring...

  • Page 21: Maximum Forces And Moments

    Installation 4 4.2.3 Maximum Forces and Moments Forces Moments Pump Model Units SX3/4 SX5/6 4.2.4 Direction of flow The direction of flow is dictated by the direction of rotation of the drive shaft. Reversing the direction of rotation will reverse the flow direction. Suction Discharge Suction...

  • Page 22: Pump Lubrication

    4 Installation 4.2.5 Pump Lubrication The pump will be supplied pre-filled with food grade (NSF-1) synthetic (PAO based) oil as standard. Oil changing: Oil level must be checked with the pump static. The oil should be changed every 3000 hrs of operation or every 2 years, whichever comes first.

  • Page 23: Baseplate Foundations

    Installation 4 4.2.6 Baseplate Foundations Pumps when supplied with a drive unit are normally mounted on a baseplate. Our standard baseplates have pre-drilled fixing holes to accept base retaining bolts. To provide a permanent rigid support for securing the pump unit, a foundation is required which will also absorb vibration, strain or shock on the pumping unit.

  • Page 24: Coupling Alignment

    4 Installation 4.2.7 Coupling Alignment Before the pump unit is installed is it important to ensure that the mounting surface is flat to avoid distortion of the baseplate, which may cause pump/ motor shaft misalignment and pump/motor unit damage. Once the baseplate has been secured, the pump shaft to motor shaft coupling alignment should be checked and adjusted as necessary.
  • Page 25 Installation 4 Assembled length Coupling size Dimension L ± 1.0 mm 30.5 TD 246-088 85.5 105.5 Recommended bolt torques Thread Diameter Torque (Nm) 200007900-4-EN-GB...

  • Page 26: Flushing Seal Arrangement And Pre-Start Up Checks

    4 Installation 4.3 Flushing seal arrangement and pre-start up checks NOTE This page is not applicable for ATEX applications. For ATEX application see ATEX addendum. A flushed seal arrangement is fitted in order to cool or clean the seal area. It is important that: - The flush is correctly connected (see below)
  • Page 27 Installation 4 Flushing fluid The choice of flushing fluid is dependent upon the fluid being pumped and duty conditions i.e. pressure and temperature. Usually water is used for cooling or flushing water soluble products. For both single and flushed mechanical seal arrangements the temperature of flush media should never allowed to exceed the maximum temperature of the pumped media.
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  • Page 29: Maintenance

    5 Maintenance 5.1 Cleaning In Place (CIP) WARNING Never touch the pump or the pipelines as they will be extremely hot! Do not subject the pump to rapid temperature changes during CIP procedures, as pump seizure can result from thermal shock. A suitable by-pass is recommended.

  • Page 30: Maintenance Schedule

    5 Maintenance 5.2 Maintenance schedule It is advisable to install pressure gauges on both sides of the pump so that any problems within the pump/pipework can be monitored. Maintenance schedule Your weekly schedule should include: • Checking the oil level in the gearcase with the pump stationary •...
  • Page 31 Maintenance 5 3. With a penlight, inspect rotor retainer blind tapped hole for contamination. If soiled, refer to cleaning procedure below 4. Remove and discard rotor retainer cup seal 5. Fit new rotor retainer cup seal 6. Fit rotor retainer and use a torque wrench to tighten to correct torque value (see Tool Requirements on page 53)

  • Page 32: Dismantling

    5 Maintenance 5.3 Dismantling NOTE Before disassembling the pump refer to safety precautions. See Parts Lists and Exploded Views on page Removing rotorcase cover. Remove rotorcase cover nuts (13) and cover (12). Removing rotors Insert a plastic/wooden block between the two rotors (17) to stop them turning.
  • Page 33 Maintenance 5 Removing static seal components Please see Primary Seals Removal and Fitting on page 44. Removing rotorcase a) For flushed mechanical seal arrangements, remove the seal housing retaining nuts and ease the seal housing from the rotorcase. b) Remove the rotorcase retaining nuts (4) and washers (4A).
  • Page 34 5 Maintenance Removing Gearcase Cover. a) Remove screws (6). b) Remove gearcase cover (5) after breaking the gasket seal then press out the lip seal (7). It is essential to renew the lip seal prior to reassembly. Removing timing gears. a) Release clamp plate screws (40) on pump series 1, 2 and 3.
  • Page 35 Maintenance 5 11 Bearing removal. a) Hold the shafts (24 and 25) in a vice using soft jaws to protect the areas where the seals will be located. b) Remove the bearing nuts (30) with a ‘sharp tap’ on a ‘C’ spanner. The nuts may be tight all the way off as they are fitted with thread locking adhesive.

  • Page 36: Assembly

    5 Maintenance 5.4 Assembly 5.4.1 Fitting Bearings to Shafts Take care not to damage shaft surfaces, in particular where the seals will be located. Ensure all fastenings are tightened to torque settings as shown in Technical Data on page 51). On series 1, 2 and 3 pumps, bearings do not require heating.

  • Page 37: Fitting Shaft Assemblies

    Maintenance 5 Allow bearings to cool (series 4, 5, 6 and 7 pumps only). Failure to do so will result in incorrectly set bearings. 1. Apply Permabond Grade 145 or equivalent locking compound to the bearing nut thread. 2. Tighten the bearing nut (30), whilst at the same time rotating the bearings (26 and 31) and spacer (32).

  • Page 38: Fitting Seal Retainers

    5 Maintenance 5.4.3 Fitting Seal Retainers Clean the rear face of the seal retainers (14), fit in position and tighten. a) Check rotor alignment is correct by referring to Checking Rotor Abutment Alignment on page 38. b) When rotor alignment is correct remove seal retainers and press new lip seals (16) into seal retainers.

  • Page 39: Fitting Timing Gears

    Maintenance 5 5.4.5 Fitting Timing Gears Slide timing gears (36) onto shafts (24 and 25), realigning timing marks. a) Before fitting the torque locking devices (38) lubricate them with gear oil. Series 1, 2 and 3 have two sets of elements. b) Series 4, 5, 6 and 7 pumps have torque locking assemblies.

  • Page 40: Adjusting Rotor Timing

    5 Maintenance 5.4.6 Adjusting Rotor Timing NOTE If the rotor timing requires adjustment (and assuming the pump has not yet been re-built), it is important to establish the cause for the rotors mistiming before proceeding. To allow timing adjustment ensure that one shaft is able to rotate within the torque locking assembly/ element.

  • Page 41: Fitting Gearcase Cover

    Maintenance 5 5.4.7 Fitting Gearcase Cover Clean the gearcase cover bore and remove all gasket material from the face. Press a new lip seal (7) into the cover (5). Apply liquid gasket to the face of the cover where it mates with the gearcase. Smear oil on the inner lip of the lip seal and carefully slide the cover over the shaft ensuring the lip seal is centred and not cut or...

  • Page 42: Fitting Primary Seals

    5 Maintenance 5.4.9 Fitting Primary Seals Refer to section 4.5 for seal fitting instructions. 5.4.10 Fitting Rotors NOTE If fitted, carefully slide the O rings (18) over the shaft spline until they fit tightly against the shaft shoulder. Locate one rotor (17) on to the drive shaft (24) with the dimple at the top Turn the rotor through 45°.

  • Page 43: Fitting Rotorcase Cover

    Maintenance 5 5.4.11 Fitting Rotorcase Cover a) Fit new rotorcase cover compression joint (11). b) Fit rotorcase cover onto rotorcase (9) and tighten rotorcase cover nuts (13). c) Refer to pump start up checks prior to operation. 200007900-4-EN-GB...

  • Page 44: Primary Seals Removal And Fitting

    5 Maintenance 5.5 Primary Seals Removal and Fitting 5.5.1 R00 Single mechanical seal Mechanical seals are fragile. Take extreme care when handling. Clean components before fitting, checking there is no damage to sealing faces. New elastomeric parts should be fitted during assembly. The R00 mechanical seal is completely front loading without need of removing rotorcase for access or replacement.

  • Page 45: R00 Single Flushed/Quench Mechanical Seal

    Maintenance 5 7. Lightly lubricate rotor sealing O-ring (18) and slide onto shaft up to the shoulder. 8. Refit the rotors and rotorcase cover. 5.5.2 R00 Single flushed/quench mechanical seal The R00 mechanical seal is completely front loading without need of removing rotorcase for access or replacement.

  • Page 46: R00 Double Flushed Mechanical Seal

    5 Maintenance 7. For SX1-5 align the two flats on the rotary seal ring with the drive flats in the rotor and gently push the rotary seal ring assembly into the rear bore of the rotor. For SX6-7 align the two slots on the rotary seal ring with the drive pins in the rotor and gently push the rotary seal ring assembly into the rear bore of the rotor.
  • Page 47 Maintenance 5 3. Lubricate and fit rotary seal ring O-ring (99) into outboard rotary seal ring (98). 4. Slide wave spring (100) along shaft through the rotorcase bore until located on the shaft shoulder. 5. Wipe clean the sealing faces with solvent. 6.

  • Page 48: Troubleshooting

    5 Maintenance 5.6 Troubleshooting Problem Probable Causes Solutions Incorrect direction of ro- √ √ Reverse motor. tation Expel gas from suction line and √ Pump not primed. pumping chamber and introduce flu- Increase suction line diameter. Increase suction head. Insufficient NPSH avail- √...
  • Page 49 Maintenance 5 Problem Probable Causes Solutions Clean the system. Unexpected solids in Fit strainer to suction line. √ √ √ √ fluid. If solids cannot be eliminated, con- sider fitting double mechanical seals. Check for obstructions i.e. closed valve. √ √ √ Discharge pressure Service system and change to pre- √...
  • Page 50 5 Maintenance Problem Probable Causes Solutions √ √ √ Worn pumping element. Fit new components. Check pressure setting and re-adjust if necessary. Rotorcase cover relief √ √ √ valve leakage. Examine and clean seating surfaces. Replace worn parts. Check for wear on sealing surfaces, Rotorcase cover relief guides etc.

  • Page 51: Technical Data

    Gear motor, 4 poles, to IEC metric standard, 50/60 Hz, suitable for frequency conversion, IP55, insulation class F. Warranty Extended 3-years warranty on SX pumps. The warranty covers all non wear parts on the condition that genu- ine Alfa Laval Spare Parts are used. 200007900-4-EN-GB...

  • Page 52: Oil Capacities

    6 Technical Data 6.2 Oil Capacities Port orientation Port orientation Pump model Vertical Horizontal Vertical Horizontal litres litres US pints US pints 0.30 0.40 0.60 0.80 0.60 0.70 1.20 1.40 1.10 1.50 2.20 3.10 1.50 2.00 3.20 4.20 3.00 4.00 6.30 8.40 4.50...

  • Page 53: Tool Requirements

    Technical Data 6 6.4 Tool Requirements Pump Model Description Tool required Socket Size (mm) Rotorcase cover nut Torque Setting (Nm) (13) Torque Setting (lbft) 14.8 28.8 28.8 28.8 28.8 77.4 77.4 Socket Size (mm) Rotor retainer (22) Torque Setting (Nm) Torque Setting (lbft) 14.8 44.3...

  • Page 54: Pump Data Table

    6 Technical Data 6.5 Pump Data Table Model Displacement Suction & Discharge Differential Maximum Maximum Pressure Capacity Capacity Connection Pressure Max Speed at rev/min at max. Size rpm m³/hr Nominal Bore Connection litres/ Size gal/ US gal/ (International diameter Std) (Standard) inch inch...

  • Page 55: Pumphead Clearance Information

    Technical Data 6 6.6 Pumphead Clearance Information Radial Clearance Front Clearance Rotor Length Back Clearance Mesh Clearance Pressure Rotor Front Back Rotor Radial Mesh Pump Model Length Clearance Clearance Diameter Clearance Clearance Min. Min. Min. Min. Min. 28.88 - 28.91 0.11 0.05 57.85...
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  • Page 57: Spare Parts

    Alfa Laval representative for availability. You can find our spare part catalogue at https://hygienicfluidhandling-catalogue.alfalaval.com. Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on use of Alfa Laval genuine spare parts. 7.1 Ordering Spare Parts When ordering spare parts, please always state: 1.

  • Page 58: Warranty - Definition

    7.3 Warranty - Definition WARNING The rules of Intended use are absolute. Use of the supplied Alfa Laval product is allowed only when in compliance with the technical data supplied with the Intended use. Differing utilisation, other than agreed with Alfa Laval Kolding A/S, exclude any liability and warranty.

  • Page 59: Parts Lists And Exploded Views

    8 Parts Lists and Exploded Views 8.1 SX1-3 Pump Range TD 242-120 200007900-4-EN-GB...
  • Page 60 8 Parts Lists and Exploded Views Pos. Qty. Denomination Pos. Qty. Denomination Gearcase Dowel Shaft, drive Stud, rotorcase retention Shaft, auxiliary Nut, rotorcase retention Bearing, rear Washer, rotorcase retention Spacer, shaft abutment Cover, gearcase Nut, bearing front Screw, gearcase cover Bearing, front Lip seal, drive end Nut, bearing front...

  • Page 61: Sx4 Pump Range

    Parts Lists and Exploded Views 8 8.2 SX4 Pump Range TD 242-121 200007900-4-EN-GB...
  • Page 62 8 Parts Lists and Exploded Views Pos. Qty. Denomination Pos. Qty. Denomination Gearcase Shaft, drive Dowel Shaft, auxiliary Stud, rotorcase retention Bearing, rear Nut, rotorcase retention Spacer, shaft abutment Washer, rotorcase retention Spacer, bearing drive end Cover, gearcase Spacer, bearing gland end Screw, gearcase cover Nut, bearing Lip seal, drive end...

  • Page 63: Sx5 Pump Range

    Parts Lists and Exploded Views 8 8.3 SX5 Pump Range 3202-0002 200007900-4-EN-GB...
  • Page 64 8 Parts Lists and Exploded Views Pos. Qty. Denomination Pos. Qty. Denomination Gearcase Shaft, drive Dowel Shaft, auxiliary Stud, rotorcase retention Bearing, rear Nut, rotorcase retention Spacer, shaft abutment Washer, rotorcase retention Spacer, bearing drive end Cover, gearcase Spacer, bearing gland end Screw, gearcase cover Nut, bearing front Lip seal, drive end...

  • Page 65: Sx6-7 Pump Range

    Parts Lists and Exploded Views 8 8.4 SX6-7 Pump Range 3202-0003 200007900-4-EN-GB...
  • Page 66 8 Parts Lists and Exploded Views Pos. Qty. Denomination Pos. Qty. Denomination Gearcase Dowel Shaft, drive Stud, rotorcase retention Shaft, auxiliary Nut, rotorcase retention Bearing, rear Washer, rotorcase retention Spacer, shaft abutment Cover, gearcase Spacer, bearing drive end Screw, gearcase cover Spacer, bearing gland end Lip seal, drive end Nut, bearing front...

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