INSTRUCTION AND MAINTENANCE MANUAL

Transcription

1 INSTRUCTION AND MAINTENANCE MANUAL 3 SCREW PUMP PZ MUM PZ ENG

2 1 GENERAL INDEX 1 General index Preamble Machine description Technical characteristic Identification Safety Handling and shipping Installation Pressure relief valve adjustment Maintenance Versione con Tuning Assembly drawing Troubleshooting Disposal Warranty Declaration of incorporation MUM PZ ENG pag. 2 di 20

3 2 PREAMBLE This manual contains instructions for machine use and maintenance. Its contents are to be used by operators trained to take necessary precautions during the complete lifecycle of the machine. The scope of the manual is to supply indications to use the machine safely and to perform ordinary maintenance operations. No extraordinary maintenance operations are mentioned in this manual, as they are considered exclusive competence of a technical assistance technician. The technician must intervene on the machine with respect to the technical characteristics of the project for which the machine has been manufactured. Reading this manual is indispensable. However, this manual cannot substitute the competence of technical personnel, which must have undergone preliminary and adequate training. The manual must be kept intact and in good conditions during the complete lifecycle of the machine. After consulting the manual, keep it in safe and protected place. If this documentation is lost or damaged, it is possible to obtain a copy from the manufacturer, indicating on the order the production batch code, the machine serial number and year of manufacture. This machine has been manufactured conforming to the directives in force in the European community and to the regulations taken in the requirements, as stated in the Declaration of Incorporation released by the Manufacturer and enclosed in the manual. The information in this manual cannot be released to third parties. Any duplication not authorized in writing by SEIM, partial or complete, obtained by photocopying, duplication or with other systems, even by electronic scanning, violates the copyright conditions and legal action can be taken. CUSTOMER CARE For any information please contact SEIM s.r.l. Via Volta, , CUSAGO (MI) ITALY Phone: ; FAX: seim@seim.it web: MUM PZ ENG pag. 3 di 20

4 3 MACHINE DESCRIPTION The PZ pump is a 3 screw pump for hydraulic oils, lubricating oils (special version for heavy fuel). Destined for multiple use such as auxiliary lubrication or cooling circuits. There are several version available for specific application (kind of fluid, viscosity, pressure, material, compatibility). Main field of application: pumps for lubrication system auxiliary cooling, with relief valve. The pump has cast iron body. SEIM s.r.l. test its pumps before the delivery. Thanks to this the pumps are tested to 100% Fig. 1 1 Suction flange 8 Pressure port 2 Pressure gauge 9 Screws 3 Pump body (cast iron) 10 End cover 4 Motor connection flange 11 Vertical foot (opzional) 5 Key 12 Relief valve adjustable 6 Main pump screw 13 Mechanical seal drain 7 Point to fix horizontal foot (Horizontal foot optional) 14 Mechanica seal pre-fill hole MUM PZ ENG pag. 4 di 20

5 4 TECHNICAL CHARACTIERISTICS Functional characteristics for standard version Delivery flow: Admissible delivery pressure *: up to 5400 l/min (up to 1425 USGPM) up to 16 bar (232 psi) from 750 to 3600 rpm Admissible suction pressure: from -0,5 to 10 bar (from -7.3 to 145 psi) For different value contact SEIM Kinematics viscosity: from 10 to 400 (cst STD (< 5000 cst special) For different value contact SEIM Admissible temperature: from 0 to 120 C (da 32 a 248 F) For different value contact SEIM Driving speed: Average noise level: until 140 C (284 F) special rpm; up to rpm up to PZ db(a) at 1800 rpm according to pump dimension Reccomended oil filtration: 60 micron max on suction side (not abrasive contaminant) ISO /16-NAS 10 Direction of rotation: Clockwise, as seen from driving side * Reduced pressure limits apply due to fluid viscosity and driving speed. Consult the performance charts for individual pump side. For different functional characteristics, please contact our sales department. For pump dimension see the technical data sheet - STE PZ - - The relief valve on the pump can be setted by the manufacturer. The ambient operating conditions are: - temperatura: 0 ~ 55 C SEIM is not responsible for the system used to operate the pump. The use of the pump for uses different from as indicated above is prohibited and is dangerous. MUM PZ ENG pag. 5 di 20

6 5 IDENTIFICATION All SEIM pumps are signed with the manufacturer name, the serial number, the year and the month of production and the production batch code. For any information, contact the manufacturer and always mention the data described above. Never change or remove the code numbers, otherwise the warranty expires. Manufacturer Pump code Pump rotation direction Serial number Respecting the rotation sense is fundamental for pump use; an incorrect rotation sense will jeopardize pump operation. PZ pumps are ABS Type Approval certified. When is required this marine certification by the customer, this tagplate is attacked to the pump body. PZ pumps are also CTR certified. When is required this certification by the customer, this tagplate is attacked to the pump body. MUM PZ ENG pag. 6 di 20

7 6 SAFETY 1.1 Correct use The pump is destined to operate with hydraulic or lubricating oil, within the temperature, viscosity and pressure limits indicated cap. 4 TECHNICAL CHARACTERISTICS. Using the pump in conditions or with different fluids other than those indicated, unless expressively authorized by SEIM, can cause dangerous situations, for which SEIM cannot be held responsible in any way whatsoever. 1.2 Individual protection device During maintenance operations, gloves and protection glasses must be worn. 1.3 General prescriptions Avoid pump station components from coming into contact with wet or humid surfaces. Avoid unauthorized personnel to enter the working area. Do not wear loose clothing or accessories, which may get entangled in moving parts (ties, bracelets, etc.) Do not wear large sleeve clothing, laces, belts or bracelets or other accessories, which may be the cause of danger. Any long hair must be gathered together in a manner to avoid dangerous situations. Avoid the oil inlet-piping coming into contact with hot objects, sharp surfaces or cutting corners. Do not overload the pump on rigid piping connections. The user must never substitute them if they are damaged. If necessary, contact professionally qualified personnel. The workplace must be kept in order and well illuminated; no liquids or traces of oil must be present. Avoid pressure overloads, which can be a risk and may damage the life of the pump. Before connecting the pump, make sure everything is completely installed. Only pump oils with a viscosity between 10 and 400 cst, with a permissible continuous outlet pressure up to 30 bars (435 psi), with an inlet pressure between -0,5 to 10 bars (from 7,3 to 145 psi) and an operating temperature from 0 to 120 C (from 32 to 248 F). For requests differing to the above, please contact SEIM. Using the pump for different uses to those indicated is forbidden and can be dangerous. For maintenance and substitution, only use original spare parts. Any installations not conforming to the specifications can compromise your safety and make the warranty void. MUM PZ ENG pag. 7 di 20

8 7 HANDLING AND SHIPPING 1.4 General conditions The pumps are normally supplied in boxes (Fig. ), separated by pressed cardboard on the inside (to avoid damage during transportation) and finally filled with packaging paper. The box is closed and strapped to a pallet and can be handled using a forklift truck (Fig. ). An adhesive label is attached to the box describing its contents. The dimensions of the packaging depend on the type of pump ordered. 1.5 Safety requirements The personnel charged to handle the load must use protective gloves and must be trained to use lifting devices. If the packaging remains outdoors during the shipping or storage operations, cover it with a tarpaulin cover (see for example Fig. ). All optional features ordered with the pump are packed separately and must be covered. Follow the instructions on the packaging before handling and opening it. Make sure that the transportation and lifting devices are able to support the weight of the packaging containing the pumps as indicated in the documentation provided with the supply. Lift the packaging only a few centimetres from the floor to avoid swinging of the load and always position the forks at the centre of gravity. Always move the load slowly during handling operations. Always check the point where the forks touch under the pallet to avoid some parts being damaged; if necessary use some polystyrene or soft wood blocks to separate the load from the forks. Never place one package containing pumps on the top of another package (Errore. L'origine riferimento non è stata trovata.): the packaging will not bear the weight. Fig. 2 Fig. 3 Fig. 4 Fig. 5 MUM PZ ENG pag. 8 di 20

9 8 INSTALLATION L installazione delle pompe mod. PZ è estremamente semplice e non richiede particolari accorgimenti. Munirsi di un mezzo adeguato di sollevamento. Open the packaging, lift the pump and bring it to the installation point. Raise it as little as possible from the ground. (fig.1). Key the half-joint after having removed the protection cap and lubricated the motor shaft with a veil of oil (fig.2). Lock the half-joint using the grub-screw (fig.3) if available on the coupling. Remove the protection caps from the inlet and outlet ports and fill the pump with the fluid to be pumped (fig.4). If you cannot pre fill the pump from the suction and pressure port, provide the piping of pre fill holes. Wait a few minutes until the pump is completely filled with the fluid. Connect the piping on the inlet and outlet ports (fig.5). Pay attention, foreign elements don t have to fall into the ports. Pre fill the mechanical seal area using the pre fill hole (fig.6). Check the direction of rotation of the pump by starting the electric motor and observing the direction of rotation of the motor fan or, if easier, the motor shaft through a hole applied in the housing: the direction of rotation must comply with the direction of the arrow placed on the nameplate Limit the first start-up to the time necessary to check that the direction of rotation corresponds to the direction indicated on the pump nameplate. This prevents partial or total damage to the pump in the case of incorrect rotation. 4 Start-up the motor after checking that all the valves on the line are fully open. At this point, the pump begins to draw fluid and to deliver the flow. Run the pump unloaded for a few minutes to facilitate the elimination of any air present in the fluid. Then regulate the pressure to the value foreseen for the system (fig.7 valve pilot operated, fig.8 valve direct operated). 7 PRESSURE If the pump does not draw the fluid, stop the motor within 30 seconds and repeat the start-up operations at intervals of a few seconds. If the problem persists, check system compliance. Protect the pump from foreign material through an appropriate filtration system. Check the level of filtration on the recommended technical reference. PRESSURE MUM PZ ENG pag. 9 di 20

10 9 PRESSURE RELIEF VALVE ADJUSTMENT The pressure relief valve is integrated into the pump with an internal recirculation and it limit the maximum pressure of the system in the case of emergency. Under normal working conditions the valve is closed. On standard pump version the valve is not setted. If the valve is setted at a specific pressure, is also sealed. On the test bench SEIM test at 100% valves and pumps. It is possible for the customer change the setting of the valve in the range of pressures specified in the datasheet. Do not change the valve components. For the valve setting see the pictures A and B. We suggest to start the valve adjustment procedure with the valve fully open. Summary table Δp (difference of pressure between start and complete discharge valve opening) depending on pump model. Δp [bar] rpm From PZ032 to PZ060 3 X X PZ072 3 X From PZ083 to PZ156 3 * pump with larger capacity; viscosity 100 cst X = the valve is able to discharge fully the flow = 100% Pilot operated valve B Direct operated valve A PRESSIONE PRESSURE PRESSURE MUM PZ ENG pag. 10 di 20

11 10 MAINTENANCE All maintenance interventions must be carried out when the pump is stopped and after disconnecting the motor power supply. Make sure to handle carefully the pump and make sure that there is no risk of accidental fall of components. SEIM declines all responsibility for damage to person or property caused by: - interventions performed not in compliance with the indications in this manual; - interventions performed by unauthorized personnel; - use of non-original spare parts. Ordinary maintenance requires the following operations, to be performed periodically: Clean the pump externally Check for leaks Tighten the nuts and screws In case of extraordinary maintenance you can find below the instructions to disassembly the motor - pump. These instructions has to be followed only by authorized personnel and can require the use of equipment not commonly used. Use also the sectional drawing that you can find in this catalogue. SEIM is not responsible for any damage caused by disassembly or by incorrect reassembly of the pump. In case of necessity or for further information please contact SEIM s.r.l. Tightening torques [Nm] M6 9,5 M8 23 M10 46 M12 79 M M Disassembly of the mechanical seal 9 Disconnect the pipe after empty the pump. Disconnect the pump from the bell-housing and extract the half coupling after unscrewing the bolts. Dismount the key from the main screw and unscrew the bolts of the connection from the motor connection flange and the pump body. Dismount the motor connection flange with light blows with a plastic hammer and the three screws (on the motor connection flange is mounted the mating 10 ring of the mechanical seal). Remove the idler screws. Remove the retaining circlip from the main screw with a light blows with a plastic hammer. Pull out the main screw and the primary ring. Remove the mating ring of the mechanical seal from the flange (fig.9). Remove the primary ring from the main screw rotating it in the opposite direction to the winding direction of the spring. Pay attention at never touch the sliding surface (fig.10). MUM PZ ENG pag. 11 di 20

12 Disassembly the pressure relief valve After unlocking the ring nut loosen the screw of the valve (fig.11). Unscrew the screws, pull out the valve flange from the body and check the o-ring; replace it if damaged (fig.11). Remove the spring and then the shutter (fig.11). Disassembly of the ball bearing In order to make this operation you have to make the instructions described In the above paragrath Dismounting the mechanical seal. Pull out the group of components, ball bearing, main screw and idler screws observing the position of signs (X) present on the central screw and the relative side, in order to facilitate the subsequent assembly sequence (fig.12). Remove the circlip and using an extractor remove the ball bearing Assembly the new ball bearing Before to assembly the pump, it is recommended to clean the components inside well. Check all the o-rings, the gasket and the mechanical seal, if damaged substitute them. Heating the ball bearing and place it on the main screw, block it with the circlip. Make sure the main screw rotates freely. Lubricate the main screw, the idler screws and assembly them in the pump body, making sure that the marks (X) of the central screw and its lateral screws are exactly in the same position they were in during dismantling (fig.13). Assembly the mechanical seal N.B.: during assembly, the lapped surfaces of the mechanical seal must not come into contact the workbench; place the primari ring and the mating ring with the seal surfaces upwards. PRIMARY RING OF THE MECHANICAL SEAL: 14 Using alcohol, wash well the seat on the motor connection flange of the mechanical seal primary ring and the o-ring of the primary ring. Using a pushing tool (material of the tool: NYLON / PTFE), mount the primary ring into the seal seat using a costant force, placement should be with the sealing face perfectly parallel to the flange (fig.14). Wet the sealing face with alcohol. Blow with air to evaporate the alcohol. Clean the seal face using a clean cloth (cellulose, not cotton) soaked with alcohol and let it evaporate. MUM PZ ENG pag. 12 di 20

13 MATING RING: Hold the main screw. Make sure that the main screw surface is completely smooth and without sharp edges. If necessary, shine the shaft with fine abrasive cloth (grain ca), soave with oil and gasoil, even if it has been grinded. Spread a veil of grease on the main screw seat seal, mount the mating ring on the main screw (fig.15) rotating in opposite direction to the winding of the spring until the stop and check the correct axial sliding (Fig.16). NO GREASE OR DIRTY MUST BE PRESENT ON THE SEALING FACE, for safety use a cloth moistened with alcohol and let it evaporate CLOSING THE PUMP: Repeat in reverse sequence the steps described in paragraph DISASSEMBLY OF THE ME- CHANICAL SEAL. Assembly the relief valve It is necessary to disassemble the pump end cover to disassemble the relief valve. Mount the obturator and the spring in their seats. Mount the pump end cover to the pump housing and tighten, in an alternating sequence, the screws. To make these operations easier, see the sectional drawing in the paragraph SECTION- AL DRAWING. After a general inspection of the pump set up on the system following the instructions described in START UP INSTRUCTIONS. 9.1 TUNING VERSION For the use in environments with percentages air / oil above the limit recommended for pumps series PZ, Seim adds to the standard configuration, a device designed to "drain" the surplus of air bubbles accumulated inside the pump. This device, to be operated during the operation of the pump, is composed by the sectional drawing shown above. To allow the air vent remove the nut n 4, unscrew the pin n 2 until the mechanical stop. Wait a few seconds and screw again the obturator (without forcing the closure) and the protection cap (n 4). MUM PZ ENG pag. 13 di 20

14 11 ASSEMBLY DRAWING PUMP PZ 32 Mechanical seal Mechanical seal N DESCRIPTION N DESCRIPTION N DESCRIPTION 1 circlip ** 15 nut 29 ball 2 circlip ** 16 nut 30 pin 3 circlip ** 17 spacer 31 pin ** 4 circlip 18 end cover 32 valve guide rod 5 circlip ** 19 lip seal * 33 obturator guide rod 6 spacer ** 20 gasket 34 plug 7 spacer** 21 key ** 35 plug 8 spacer * 22 spring 36 plate 9 main screw ring ** 23 spring 37 mechanical seal jc * 10 seal ring ** 24 o-ring 38 mechanical seal un * 11 anti-rotating element 25 o-ring ** 39 main screw ** 12 pump body 26 o-ring * 40 idler screw ** 13 plug 27 obturator 41 hexagonal socket head screw 14 ball bearing * 28 rivet (spare part kit: *basic - **superior - standard) MUM PZ ENG pag. 14 di 20

15 POMP PZ Mechanical seal Mechanical seal N DESCRIPTION N DESCRIPTION N DESCRIPTION 1 spacer 12 spacer * 25 pin 2 spacer 13 spacer ** 26 valve guide rod 3 circlip ** 14 motor connection flange 27 plug 4 circlip 15 end cover 28 nameplate 5 tie rod 16 key ** 29 mechanical seal jc * 6 pump body 17 spring 30 mechanical seal un * 7 ball bearing * 18 o-ring 31 main screw ** 8 nut 19 o-ring * 32 Idler screw ** 9 nut 20 o-ring 33 hexagonal socket head screw 10 nut 21 foot (option) 34 obturator guide rod 11 spacer 22 obturator 35 anti-rotating element 10 nut 23 spacer 11 spacer 24 rivet (spare part kit: *basic - **superior - standard) MUM PZ ENG pag. 15 di 20

16 PUMP PZ DIRECT OPERATED VALVE PILOT OPERA- TED VALVE Mechanical seal Mechanical seal N DESCRIPTION N DESCRIPTION N DESCRIPTION N DESCRIPTION 1 spacer 14 spacer 27 o-ring 40 valve guide rod 2 circlip ** 15 spacer** 28 obturator 41 plug 3 circlip 16 spacer * 29 obturator 42 nameplate 4 anti rotating element 17 motor connection flange 30 obturator guide rod 43 mechanical seal jc * 5 tie rod 18 end cover 31 spacer 44 mechanical seal un * 6 obturator guide rod 19 ring nut 32 spacer 45 pilot valve 7 pump body 20 sprig 33 horizontal foot (option) 46 main screw ** 8 ball bearing * 21 key ** 34 vertical foot (option) 47 idler screw ** 9 nut 22 spring 35 rivet 48 hexagonal socket head screw 10 nut 23 spring 36 washer 49 hexagonal socket head screw 11 nut 24 o-ring 37 seal ring 50 hexagonal socket head screw 12 nut 25 o-ring 38 locking washer 13 nut 26 o-ring * 39 pin (spare part kit: *basic - **superior - standard) MUM PZ ENG pag. 16 di 20

17 PUMP PZ DIRECT OPERATED VALVE Mechanical seal PILOT OPE- RATED VALVE Mechanical seal N DESCRIPTION (PZ 72) N DESCRIPTION (PZ 72) 14 circlip ** 32 seal ring N DESCRIPTION N DESCRIPTION N DESCRIPTION N DESCRIPTION 1 circlip 13 end cover 25 obturator 37 plug 2 obturator guide rod 14 ring nut 26 pin 38 nameplate 3 pump body 15 ring nut ** 27 foot (option) 39 mechanical seal jc * 4 ball bearing * 16 sprig 28 foot (option) 40 mechanical seal un * 5 nut 17 key ** 29 rivet 41 lubricating tube 6 nut 18 spring 30 washer 42 pilot valve 7 nut 19 spring 31 washer 43 main screw ** 8 spacer ** 20 o-ring 32 seal ring 44 idler screw ** 9 spacer * 21 o-ring 33 locking washer ** 45 hexagonal socket head screw 10 spacer 22 o-ring * 34 anti rotating element 46 hexagonal socket head screw 11 spacer (only PZ 102) 23 o-ring 35 pin 47 hexagonal screw 12 motor connection flange 24 obturator 36 valve guide rod (spare part kit: *basic - **superior - standard) MUM PZ ENG pag. 17 di 20

18 2 TROUBLESHOOTING PROBLEM Incorrect rotation direction Phase connection error Delivery flow-rate too low The valves on the line are not fully open The maximum pressure valve value is calibrated too low The filter is clogged or foreign bodies reduce the flow Pressure too low Leaks in the piping The outlet pressure is too low The maximum pressure valve value is calibrated too low Difficult motor start-up The pressure required by the system is too high Oil is too cold The motor is not suitable for the power required The motor calibration relay is too low The pump is noisy when operating SOLUTION For three-phase motors, the two wires used to connect the electrical phases must be inverted Open the valves and restart the pump Loosen the adjustment screw until it can be turned manually and start the pump for a few minutes with no pressure. Then tighten the adjustment screw until the calibration value desired is reached. Check the plant. Check that no foreign bodies are inside the pump. Check the piping and identify any leaks Substitute the pump with a higher delivery flow-rate pump Loosen the adjustment screw until it can be turned manually and start the pump for a few minutes with no pressure. Then tighten the adjustment screw until the calibration value desired is reached. Check the plant Start-up the pump without pressure until the oil returns to its normal temperature. Bring the system back to its working pressure. Substitute the motor with a higher power rating motor Increase the relay intervention threshold Check for: No air is present in the system The piping is not too long or the piping section diameter is too small The filter is not clogged or that the inlet valve is not closed The inlet pressure is insufficient The alignment between the motor and the pump is correct The pump is not worn or damaged. Contact the manufacturer. MUM PZ ENG pag. 18 di 20

19 3 DISPOSAL When a pump cannot be repaired or must be demolished, it cannot just be disposed of; it must be sent to a dismantler to be disassembled and to have its materials separated. Most parts of the pump can be easily recycled. When the pump is placed out of service, it is recommended to separate the materials for reuse or for separated collection for disposal. No materials making up the pump are toxic or dangerous for the health of the operators; therefore, they can be handled without any particular precautions. The disposal of equipment and components at the end of their lifecycle must be carried out by qualified personnel trained about correct handling methods and if necessary for machine disassembly. 4 WARRANTY All SEIM pumps have a 12 month operating warranty and/or 18 months from the date of delivery, unless otherwise agreed in writing. The warranty covers all manufacturing and material defects, and foresees the substitution of spare parts or the repair of defective parts. The material to be repaired must be sent CARRIAGE FREE. Once the pump has been repaired, it will be sent CARRIAGE FORWARD to the customer. The warranty does not cover any intervention by SEIM technicians or pump disassembly from the place it is installed. If, for practical reasons, a technician is sent to the premises of the customer, the customer will be charged working costs at current prices, travelling and living costs. THE WARRANTY DOES NOT INCLUDE: Parts subject to wear; Faults caused by bad use; Faults caused by external agents; Faults caused by negligence or lack of maintenance. WARRANTY FORFEITURE: In case of arrears or other breaches of contract; Any repairs or modifications made to the pumps without written consent by SEIM,; Tampering with or cancellation of the pump Serial Number; When damage is caused by improper use and other causes not due to normal working conditions; If the pumps are disassembled, tampered with or repaired by personnel not authorized by SEIM; In the case that the pumps are used for different purposes other than the purposes described in this manual. Repairs performed under warranty do not interrupt the warranty duration. MUM PZ ENG pag. 19 di 20

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