Original Instructins Safety and Operatin These instructins shuld be read thrughly by all persnnel invlved with pump peratin prir t pump installatin, peratin, r maintenance. Manual N. SRM00100 Rev. 01 (12-0064) February 2012
Cntents A Abut this Dcument...3 A.1 Target Grups...3 A.2 Other Applicable Dcuments...3 A.3 Warnings and Symbls...4 B. General Descriptin / Designatin / Labeling...5 B.1 General Descriptin...5 B.2 Designatin...5 B.3 Labeling...6 C D Safety...7 C.1 Imprtant Ntice...7 C.2 Operating Instructins f the Operating Party...7 C.3 Intended Use...7 C.4 Qualificatins f Persnnel...8 C.5 General Safety Instructins...8 C.6 Installatin / Machine Specific Safety Instructins...8 C.7 Safety Ntes n Start-up...8 C.8 Operatin and Maintenance Safety...9 C.9 Airbrne Nise...9 C.10 Pumps with Magnetic Cupling...9 Transprt / Strage...10 D.1 Safe Lifting and Transprtatin f Pumps...10 D.2 Strage / Spare Parts...10 E Installatin / Start-up...11 E.1 General...11 E.2 Tls...11 E.3 Installatin / Preheating / Start-up...11 E.3.1 Lubricatin, Preparatin...11 E.3.2 Preheating, Cling...12 E.3.3 Munting / Alignment / Installatin...12 E.3.4 Start-up...12 F Operatin / Shutdwn / Restart...13 F.1 Heating, Cling During Operatin...13 F.2 Shutdwn...13 F.3 Restarts...14 G Maintenance...14 G.1 Perfrming Maintenance...14 G.2 Ordering and Installatin f Parts / Spare Parts...15 H Failure...15 I Trubleshting...15 J EC Declaratin f Cnfrmity...15 ATTENTION If peratin f this pump is critical t yur business, we strngly recmmend yu keep a spare pump in stck at all times. As a minimum, a seal kit (-rings, gaskets, and shaft seal) shuld be kept in stck s pump refurbishment after internal inspectin can be accmplished. 2
A Abut this Dcument This manual: Is part f the Im Pump Applies t all Im Pump mdels / series Prvides instructins describing safe and apprpriate methds fr general installatin, peratin and truble shting f the pump i NOTE Cntract terms may have specific prvisins which vary frm what is shwn in this manual! Shuld any questins arise which are nt answered by these instructins, refer t the crrect Original Installatin, Care and Maintenance Instructins. A.1 Target Grups Target grup Operating cmpany Specialized Persnnel, Fitters, Operatrs Duty Keep this manual available at the site f peratin f the equipment, including fr later use Ensure that persnnel read and fllw the instructins in this manual and the ther applicable dcuments, especially all safety instructins and warnings. Observe any additinal rules and regulatins referring t the pump r system. Read, bserve and fllw this manual and the ther applicable dcuments, especially all safety instructins and warnings. A.2 Other Applicable Dcuments Dcument Prduct Service Manual Original Installatin, General Maintenance and Trubleshting Manual (SRM00101) Assembly Drawings, Parts List / Bill-f-Materials ATEX - additinal instructins (if applicable) Order Details, data sheet Prduct Brchures, Engineering Data Sheets Supplier dcumentatin Declaratin f cnfrmity Purpse Detailed instructins fr inspectin, disassembly, repair and reassembly f a specific pump mdel r series. Detailed instructins fr installatin, general maintenance and trubleshting. Drawings f the pump assembly and Sub-assemblies Parts List and Bill-f-Materials listing cmpnents Operatin in explsin-hazard areas Technical specificatins, cnditins f peratin Technical specificatins, cnditins f peratin Technical dcumentatin fr parts supplied by subcntractrs Cnfrmity with standards, cntents f the declaratin f cnfrmity 3
A.3 Warnings and Symbls Warning Level Risk Level Cnsequences f disregarding the warning DANGER Immediate Acute Risk Death, Serius Bdily Harm Ptential Acute Risk Death, Serius Bdily Harm CAUTION Immediate Hazardus Situatin Minr Bdily Harm, Material Damage Ptentially Hazardus Situatin Minr Bdily Harm, Material Damage i NOTE Symbl Meaning Instructin I Safety Warning Take nte f all infrmatin highlighted by a Safety Warning Sign and fllw the instructins t avid damage t equipment, injury t persnnel r death. Multiple Step Instructin Infrmatin, Ntes Strng Magnetic Field Peple with pacemakers prhibited within 3 meters Electrical Hazard Cntact with water can cause shck. D NOT tuch with wet hands. Always unplug when nt in use. 4
B. General Descriptin / Designatin / Labeling B.1 General Descriptin B.1.1 Im 3-Screw General Descriptin Im series pumps are single ended r duble ended psitive displacement, rtary screw pumps cnsisting f a precisin bred husing r husings that enclse a drive screw (pwer rtr) and tw r mre intermeshing driven screws (idler rtrs). These screws, when rtating, frm a successin f clsures r cavities. As they rtate, fluid is mved axially frm inlet t utlet prt in a cntinuus, unifrm flw with minimum fluid pulsatin and lw pump nise. Fluid flwing thrugh the pump prvides lubricatin fr mving parts. B.1.2 CIG General Descriptin The CIG is a psitive displacement, internal gear pump. Fluid enters the inlet chamber and is carried acrss a crescent t the discharge chamber where it is frced ut f the stage by the meshing f the internal and external gear teeth. Fluid flwing thrugh the pump prvides lubricatin t the mving parts. The pump can be multi-staged t increase its pressure capability. B.2 Designatin This manual applies t all Series f Im pumps, including all 3-Screw pumps and CIG pumps. B.2.1 Im 3-Screw Designatin (Except 3G) B.2.2 Im 3-Screw 3G Designatin 5
B.2.3 CIG Designatin B.2.4 2BIC Designatin B.3 Labeling B.3.1 CE Nameplate 6
B.3.2 ATEX Nameplate C Safety C.1 Imprtant Ntice Read these perating instructins befre installatin and/r start-up f the pump. Installatin, peratin, and maintenance instructins must be crrectly and strictly fllwed, else, injury t persnnel r serius damage t the pump culd result. Im Pump cannt accept respnsibility fr unsatisfactry perfrmance r damage resulting frm failure t cmply with instructins. This manual will nt cver all situatins which might arise with regard t installatin, peratin, inspectin, and maintenance f the equipment supplied. Im Pump assumes the persnnel assigned t install, perate and maintain the supplied equipment have sufficient technical knwledge t apply generally accepted safety and peratinal practices, which may nt be therwise cvered. Every effrt was made t prepare the text f this manual s that technical infrmatin is cnveyed in easy t understand wrding. C.2 Operating Instructins f the Operating Party As the perating party, yu are respnsible fr creating specific perating instructins fr yur persnnel based n yur cmpany s specific perating cnditins. Use this manual t help build yur wn detailed set f instructins. C.3 Intended Use Using the pump fr prcesses ther than thse fr which it is intended culd result in pump failure r persnal harm. The Im Pump is a precisin device, and is designed t be used as such. If there is a need t perate the pump in a way that is utside the riginal, published specificatins, cntact Im Pump prir t peratin fr assistance and recmmendatins. 7
C.4 Qualificatins f Persnnel Only trained peratrs shuld be used fr start-up and peratin f the pump. Only trained, specialized persnnel shuld perfrm installatin, maintenance, disassembly, r reassembly f the pump. C.5 General Safety Instructins Only trained peratrs r trained, specialized persnnel may handle r perate the pump. Adhere t the perating limits prvided in the Im specificatins r with the rder dcumentatin. Always wear prper persnal prtective equipment. (i.e. Safety glasses, steel-ted shes, face shield, prtective clthing, glves, respiratr, dust mask, etc., as required fr safe practices) CAUTION D nt run the pump dry, r with n inlet fluid flw. Make sure the pump is nly perated with, and never withut, liquid filling the pump husing. DANGER D nt remve safety guards r ther prtective devices prir t installatin r during peratin. C.6 Installatin / Machine Specific Safety Instructins Only use the pump as intended, while remaining aware f safety risks, and in adherence t the instructins in this manual. Be certain all safety devices, machine safety guards, prtective electrical cnnectins, temperature mnitring devices, pressure mnitring devices and sealing apparatus are installed and peratin prir t starting the pump. CAUTION D nt perate the pump while the valves in the system are clsed. Pumps may nt be used with fdstuffs, unless specifically adapted fr that purpse. Applicatin fr pumping fdstuffs must have been specified in the riginal purchase rder. In rder t ensure nrmal functining f the pump and system, mnitr the pressure at the inlet and the utlet f the pump. The mnitring lcatins shuld be in the inlet and utlet prt cnnectins / flanges, r immediately adjacent t thse cnnectins / flanges. Mnitr the pump temperature, after installatin and during peratin. Nte sudden changes in temperature which d nt fllw sudden changes in the temperature f the prcess liquid. If sudden temperature changes f the pump ccur, shut dwn the pump peratin and cntact trained, specialized persnnel fr inspectin and maintenance. C.7 Safety Ntes n Start-up Check t insure that all prcess safety devices are in place and peratinal. Be certain the pump is fully lubricated and full f fluid prir t starting the mtr, and that fluid can and will freely flw int the inlet. Be certain the pump temperature has fully reached the prcess temperature prir t starting the mtr. Heat sak the pump sufficiently t ensure all recesses are at prcess temperature. 8
During start-up, start the mtr with a lw-speed set pint if pssible, then gradually increase speed t the intended perating speed. An acceleratin rate f 200 rpm / sec r less is recmmended; 50 rpm / sec is best, allwing ample acceleratin time fr dwnstream apparatus t fill gradually with fluid, and fr pressure t rise slwly. C.8 Operatin and Maintenance Safety i NOTE The manufacturer s warranty will be vid if any part is replaced, r the pump is mdified in any way, withut permissin frm Im Pump. DANGER Dead-head cnditin ccurs when the there is a blckage upstream and the pump attempts t reach the maximum pressure achievable at a given speed, with a given fluid viscsity. Reaching the dead-head cnditin may cause the pump t fail, r fr piping limits t be expsed. Dwnstream pressure can change rapidly nce the pump is started. If the dwnstream flw passages are blcked r valves are clsed, the pump will likely reach dead-head cnditin befre valves can be pened r the blckage remved. i NOTE Only trained, specialized persnnel are qualified t perfrm maintenance, which includes, but is nt limited t: Inspectin Repair Assembly Disassembly Cntact Im Pump fr infrmatin n training persnnel. Measure the pump temperature after installatin, and mnitr temperature during peratin. Rapid changes in temperature, while prcess temperatures and ambient temperatures are stable, signals a pending failure. Make use f every prvided temperature measurement cnnectin pint, i.e. thermcuple munting pints, etc. C.9 Airbrne Nise Airbrne nise levels will be less than r equal t 70 dba unless therwise stated in the individual pump Prduct Service Manual. C.10 Pumps with Magnetic Cupling Magnetic cuplings use strng permanent-magnets, which generate a strng magnetic field. The installatin must be carried ut nly by trained, specialized persnnel. All installatin instructins must be strictly fllwed. Mdificatins r changes t the magnetic cupling, r its cmpnents, are nt allwed. The manufacturer des nt take respnsibility fr damage caused by imprper use. 9
DANGER In areas where permanent magnetic cuplings are handled r stred with pen access, persns with heart pacemakers shuld keep a safety distance f 3 meters. Fr permanent magnetic cuplings assembled within a pump a safety distance f 1 meter is sufficient. Installatin and maintenance must be perfrmed by trained, specialized persnnel, and must always take place during cmplete shutdwn in an un-pressurized cnditin. The drive unit must be secured against switching-n (with signs, switching ff electricity t pwer supply,) in rder t avid serius injuries. Danger f crushing! D nt reach inside the wrking area during the peratin f the cupling. Fr prtectin against accidental cntact, apprpriate machine guards must be installed and security must be maintained. CAUTION Magnetic data carriers (bank cards, hard drives and ther electrnic devices) may becme unreadable and shuld be kept away frm the magnetic field f the magnetic cupling. D Transprt / Strage D.1 Safe Lifting and Transprtatin f Pumps DANGER Death r crushing f limbs caused by falling r verturning lads! Bdily harm can ccur if excessive weight is lifted r mved incrrectly! Prtectin frm ht surfaces and ht liquids must be prvided by the peratr! Take care nt t drp the pump. Pump weights are clearly and durably marked nt the pump surface. Read and cnsider the weight prir t attempting t lift r mve the pump. D nt attempt t lift pumps heavier than 25 kg withut the use f a crane r ther type f lifting assist device. Only qualified persnnel may transprt pumps weighing mre than 25 kg. When wrking with pumps that are ht, wear prper prtective equipment and nte that ht fluid may flw frm the pump. Guard against skin cntact with ht fluids, r with a ht pump. Fllw all precautins f the fluid manufacturer in the handling f the fluid. D.2 Strage / Spare Parts In the event that an Im Pump needs t be stred, always prtect the pump against water and ther cntaminants. Stre the pump in a clean, dry, and warm envirnment. Pumps are delivered with ISO 32, PL-2, r ther suitable lubricant (unless specifically prhibited n the custmer rder,) and with prtective cvers in, r ver, all penings. These cvers shuld remain in place during the munting and alignment prcedures, as lng as pssible. Remve the cvers just prir t attaching system piping t the pump. If the pump is t be stred at an elevated temperature r in a challenging envirnment, r if they are t be stred fr mre than six mnths, cntact Im Pump fr apprpriate strage prcedures. 10
While string spare parts, always prtect the parts frm water and cntaminants. Stre the parts in a clean, dry, and warm envirnment. Spare parts shuld be lightly cated with rust preventative il and sealed in an air tight cntainer. E Installatin / Start-up E.1 General Only trained, specialized persnnel can crrectly perfrm installatin and start-up f Im pumps. Pumps shuld be carefully unpacked t make sure that the shipment is cmplete. If any items are missing r damaged, the freight carrier and Im shuld be ntified immediately. While the pump is cmpsed f steel r ther durable metal, it is a precisin instrument. Drpping the pump, r striking it with a hard material, can cause serius damage t the cmpnents. Many pump materials are thrugh-hardened t maximum hardness, resulting in a brittle cnditin. Treat them as yu wuld any precisin gauging instrument. CAUTION D nt run the pump dry r with n inlet fluid flw. Make sure the pump is nly perated with, and never withut, liquid filling the pump husing. On critical r dangerus equipment, prvide safety and emergency systems t prtect persnnel and prperty frm injury due t pump malfunctin. If pumped liquids are flammable, txic, crrsive, explsive r therwise hazardus, prvide fr safety in the event f leakage r malfunctin. DANGER BEFORE wrking n equipment, all pwer t equipment must be discnnected and lcked-ut. E.2 Tls The prcedures mentined in this manual may require mechanic s hand tls, dial indicatrs and straightedges fr alignment, suitable lifting devices such as slings r straps, lifting-assist devices r pry-bars. If the pump is made frm sfter materials, such as brnze, nickel, r titanium allys r austenitic stainless steels, the tls used shuld be brass r cpper, in rder t prevent damaging the pump. E.3 Installatin / Preheating / Start-up If at any time during peratin the pump des nt appear t be running smthly, r unusual nise is heard, stp the pump immediately, t limit internal damage, and cntact Im. E.3.1 Lubricatin, Preparatin Im pumps are shipped filled with ISO 32, PL-2, r ther rust preventative lubricant as specified. If n special requirements are nted, the lubricant is ISO 32 r PL-2. 11
When readying the pump fr service, determine whether the lubricant in the pump is suitable fr intrductin int the prcess. Additinal infrmatin n ISO 32 r PL-2 can be fund at www.impump.cm r by cntacting Im Pump. It is imprtant the lubricant des nt leave carbn residue when heated and evaprated. All rganic ils and many synthetic ils will leave carbn residue when evapratin ccurs. Carbn residue has the appearance f a baked-n, enamel finish, and has the same effect as if a strng adhesive was intrduced int the pump. Drain the excess fluid frm the Im Pump, and flush the lubricant if there are cncerns abut cntaminatin f the prcess line, r if there are cncerns abut use f the lubricant at perating temperature. After flushing, the pump must be lubricated internally. Pur a prcess-cmpatible, temperature-cmpatible lubricant int the inlet prt and turn the pump drive shaft by hand until the lubricant flws frm the discharge prt. E.3.2 Preheating, Cling D nt allw the pump t change temperature rapidly. D nt apply pen flame t a pump. D nt allw leaking fluid t catch fire. D nt expse the pump t liquid nitrgen r ther extremely cld substances. D nt attempt t quench a ht pump by applying water r ther cl liquid t the surface. If the pump is t be preheated r cled prir t installatin, heat r cl the pump t the perating temperature by use f an apprved methd, such as a band heater, bar heater, ven, cling r envirnmental chamber, liquid bath r heating jacket, which can fully reach the perating temperature f the pumping system. Mnitr the pump temperature and ensure the target temperature has been met and maintained. Allw ample time t heat-sak the pump thrughly and evenly (including the seal arrangement). E.3.3 Munting / Alignment / Installatin Munting, alignment and installatin f the pump shuld nly be perfrmed by trained, specialized persnnel in cnjunctin with the apprpriate Original Installatin, Care and Maintenance Instructins. E.3.4 Start-up Cnsult the Installatin, General Maintenance and Trubleshting Manual (SRM00101) fr full start-up instructins. If perating temperatures exceed 60 C (140 F), measures must be taken t avid skin cntact. Flush ut the plumbing system befre cnnecting the pump. Fluid entering the pump shuld be filtered t limit particle size t ½ the rtr clearances in the pump during peratin. Cnsult the factry. Rtate the pump drive shaft by hand after munting and fully tightening the munting blts. The shaft shuld turn easily. 12
I Make sure fluid freely enters the pump befre starting. Be sure t apply sufficient psitive inlet pressure t prevent cavitatin during peratin. Be sure inlet valves are pen. Be certain all guards and safety apparatus are installed cmpletely prir t start-up. Cnnect all pressure mnitring and temperature mnitring equipment and cnfirm they are functining crrectly. Be certain all dwn-stream valves, etc., are pen. Start mtr at the intended perating speed. Slwly clse the dwnstream valves t allw fr gradual pressure rise. If the pump uses Packing seals: NOTE Slight leakage is necessary t lubricate the packing during peratin. If nt apprpriately cllected, packing leakage may make flr slippery and/r expse persnnel t hazardus fluids. Cllect packing leakage prperly and safely. Tighten the packing fllwer screws in a crssing pattern, gradually, until the packing is evenly cmpressed and the leakage diminishes t near zer, then lsen each f the screws, gradually, ¼ turn at a time, until slight leakage ccurs. Slight leakage is necessary in rder t lubricate the packing and the shaft. Be certain t adjust the packing fllwer prperly. D nt ver-tighten the packing fllwer. Over-tightening will cause damage t the packing and the shaft. Other sealing ptins are available. Re-adjust the packing fllwer several times thrugh the running-in perid, until the seal is thrughly seated and the rate f leakage is stable. F Operatin / Shutdwn / Restart F.1 Heating, Cling During Operatin If the pump is t be perated utside f rm temperature (10 C 45 C), care must be taken t ensure the prcess temperature is met and maintained prir t and during peratin. Mnitr the pump temperature and ensure the target temperature has been met and maintained. Allw ample time fr the pump t adjust and stabilize. Ensure any temperature changes ccur gently, thrughly and evenly (including the seal arrangement). Prtect the pump frm thermal shcks f greater than 28 C (50 F) / sec. This culd ccur frm liquid entering the pump, frm rapid changes in the temperature f the envirnment f frm fire. Rapid temperature changes must be avided. Preheating is required when a pump s perating temperature is greater than 28 C (50 F) abve ambient temperature. F.2 Shutdwn The pump may need t be purged f the prcess fluid during shutdwn. Use f a purging liquid (an inert, lubricating liquid which is safe t the pump and persnnel,) is recmmended, rather than simply attempting t drain the prcess fluid frm the pump. Run the pump slwly during the purging prcess in rder t ensure n damage ccurs. 13
F.3 Restarts Separate the cupling cmpnents, cnnecting the pump shaft t the gearbx r mtr, and turn the pump by hand, r with a wrench, when cmpleting the purging and draining. If n purging liquid is available, and the pump will be run in rder t facilitate draining, be cautius t cmplete the peratin in less than 1 minute. If the pump is t be stred, r if it will sit fr a lng perid withut peratin r prtectin, apply rust preventative il t all internal and external surfaces. On restart, fllw the prcedures fr start up, frm previus sectin. CAUTION Take care the prduct has nt changed prperties. Ensure the fluid is still capable f prviding lubricatin t the pump internal cmpnents. Restart slwly and gradually. G Maintenance G.1 Perfrming Maintenance Seal failure will eventually ccur. Develp a plan t deal with this situatin. Take apprpriate safety measures if liquid is hazardus. BEFORE starting any maintenance prcedure, d the fllwing: Shut ff all pwer switches and circuit breakers. Remve any electrical service fuses. Lck electrical service panel supplying pwer t driver. Shut, wire r chain, and lck all valves in pump inlet/utlet piping If applicable, shut ff any steam r ther fluid supply lines t the pump. Visually check equipment frequently fr signs f damage r leakage frm shaft seals, gaskets r O-rings Be sure all cnnectins are tight. If seal leakage is mre than abut 10 drps per hur per seal, shut dwn equipment and repair r replace necessary parts. Shaft seals have a limited, finite life which is affected by perating cnditins and envirnment. Expect them t wear and eventually fail. When leakage becmes unacceptable, replace the seal unit with the crrect replacement unit, ne cmpatible with pump s perating cnditins. Dirty liquids will reduce seal life. Packing seals shuld be replaced when all packing fllwer travel is exhausted r when packing is damaged and leakage cannt be cntrlled. Where pump ut-f-service time is f vital cncern and dwn-time must be minimized, kits f spare parts and seals shuld be acquired befre needed and retained n-site. Only trained, specialized persnnel, using the apprpriate Original Installatin, Care and Maintenance Instructins, can perfrm maintenance, which includes, but is nt limited t, Inspectin, Repair, Assembly and Disassembly. Cntact Im Pump fr infrmatin n having persnnel trained. 14
G.2 Ordering and Installatin f Parts / Spare Parts When cntacting Im Pump regarding replacement parts, be prepared t prvide the pump s markings and the assembly drawing as instructed belw: Frm the markings n the pump, recrd the pump mdel number, serial number and weight. Frm the assembly drawing r instructin manual, prvide the names fr the replacement part(s). Give the abve infrmatin t yur Im service representative. Installatin f spare parts shuld nly be perfrmed by trained, specialized persnnel in cnjunctin with the apprpriate Original Installatin, Care and Maintenance Instructins. H Failure All failures can be investigated and serviced thrugh Im Pump s repair r warranty service departments. I Trubleshting Trubleshting shuld be dne by trained, specialized persnnel in cnjunctin with the General Maintenance and Trubleshting Manual (SRM00101). Im Pump can als be cntacted with assistance in trubleshting. J EC Declaratin f Cnfrmity EC Declaratin f Cnfrmity is included with the dcuments prvided with the pump. 15
COLFAX CORPORATION Im Pump 1710 Airprt Rad Mnre, NC USA 28110 tel 704.289.6511 email custmercare@clfaxfcrp.cm web www.impump.cm COLFAX, ALLWEILER, BARIC, COLFAX BUSINESS SYSTEM, FAIRMOUNT AUTOMATION, HOUTTUIN, Im, LSC, ROSSCOR, TUSHACO, WARREN and ZENITH are registered trademarks f the Clfax Crpratin r its subsidiaries in the U.S. and/r ther cuntries. 2011 Clfax Crpratin. All rights reserved.