Progressing cavity pump Type MX 50R Assembly and operation manual

MX

KNOLL Maschinenbau GmbH Schwarzachstrasse 20 D-88348 Bad Saulgau Tel. + 49 (0) 7581/2008-0 Fax + 49 (0) 7581/2008-140 [email protected] www.knoll-mb.de Copy of original operating instructions

2

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Table of contents 1

2

3

4

5

6

7

User information...................................................................................................................................... 5 1.1

User guide................................................................................................................................ 5

1.2

Symbols used...........................................................................................................................5

1.3

General information..................................................................................................................5

1.4

Customer service..................................................................................................................... 5

Safety.......................................................................................................................................................6 2.1

Safety instruction labels........................................................................................................... 6

2.2

Personnel qualification and training......................................................................................... 6

2.3

Changes from the original status..............................................................................................6

2.4

Dangers resulting from nonobservance of safety instructions..................................................6

Description of machine and functions......................................................................................................7 3.1

Normal use............................................................................................................................... 7

3.2

Improper use............................................................................................................................ 7

3.3

Application area........................................................................................................................7

3.4

Layout.......................................................................................................................................8

3.5

Mode of operation.................................................................................................................... 8

3.6

Type plate.................................................................................................................................9

3.7

Type code...............................................................................................................................10

3.8

Technical data........................................................................................................................ 11

3.9

Noise emission data............................................................................................................... 11

Transport and storage........................................................................................................................... 12 4.1

Transport................................................................................................................................ 12

4.2

Storage...................................................................................................................................13

Setup and installation............................................................................................................................ 14 5.1

Setup...................................................................................................................................... 15

5.2

Installation.............................................................................................................................. 16

Start-up..................................................................................................................................................17 6.1

Before startup.........................................................................................................................18

6.2

Checking the direction of rotation...........................................................................................18

6.3

Switching on........................................................................................................................... 19

6.4

Switching off........................................................................................................................... 19

6.5

Checks during operation........................................................................................................ 20

Repair.................................................................................................................................................... 21 7.1

Cleaning the pump................................................................................................................. 22

7.2

Loosening the release shaft................................................................................................... 22

7.3

Pump housing........................................................................................................................ 23

7.3.1

Removing the pump housing..................................................................................................23

7.3.2

Installing the pump housing....................................................................................................24

7.4

Pump assembly......................................................................................................................25

7.4.1

Removing the pump assembly with joint and release shaft................................................... 25

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3

8

9

7.4.2

Clamp pump assembly in mounting plate.............................................................................. 26

7.4.3

Disassembling the release shaft............................................................................................ 27

7.4.4

Removing the joint..................................................................................................................28

7.4.5

Removing the rotor.................................................................................................................29

7.4.6

Replacing the stator............................................................................................................... 29

7.4.7

Installing the rotor...................................................................................................................30

7.4.8

Installing the pump assembly with joint and release shaft..................................................... 31

7.5

Shaft seal............................................................................................................................... 32

7.5.1

Replace product-side axial face seal......................................................................................33

7.5.2

Replacing the axial face seal..................................................................................................36

7.5.3

Replacing the shaft seal......................................................................................................... 37

7.5.4

Dismantling the packing gland............................................................................................... 39

7.5.5

Replace packing gland........................................................................................................... 40

7.5.6

Installing the packing gland.................................................................................................... 40

7.5.7

Adjusting the gland packing................................................................................................... 41

7.6

Drive....................................................................................................................................... 42

7.6.1

Removing the drive................................................................................................................ 42

7.6.2

Installing the drive.................................................................................................................. 42

Optional accessories............................................................................................................................. 43 8.1

Cleaning connection...............................................................................................................43

8.2

Heating jacket.........................................................................................................................44

8.2.1

Removing the heating jacket.................................................................................................. 45

8.3

Sensors.................................................................................................................................. 46

8.3.1

Installing the diaphragm seal..................................................................................................46

8.3.2

Installing temperature sensor................................................................................................. 46

8.4

Assembly tools....................................................................................................................... 47

Eliminating system faults....................................................................................................................... 48 9.1

10

11

12

Maintenance.......................................................................................................................................... 50 10.1

Maintenance intervals............................................................................................................ 50

10.2

Daily....................................................................................................................................... 50

10.3

After 1500 operating hours.....................................................................................................51

10.4

After 3000 operating hours.....................................................................................................51

Drawings................................................................................................................................................52 11.1

Replacement part drawing..................................................................................................... 52

11.2

Spare-parts lists..................................................................................................................... 52

Disposing of the system.........................................................................................................................53 12.1

13

4

Fault table...............................................................................................................................48

Disposal..................................................................................................................................53

EC Declaration of Conformity................................................................................................................ 54

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1

User information

1.1

User guide Please read the installation and operating instructions prior to initial commissioning in order to prevent damage due to operator error. Make sure that the installation and operating instructions are readily available at the installation site.

1.2

Symbols used See chapter on safety

Important information for operators and technicians

1.3

➾

Prerequisites

➣

Results

General information Unqualified personnel are forbidden from working on the product! Do not remove safety devices. Follow all legal instructions.

1.4

Customer service Service Tel.

+49 (0) 7581 / 2008-353

during business hours

Tel.

+49 (0) 160 / 2822008

outside business hours

Monday - Thursday

5:00 p.m. - 9:00 p.m.

Friday

3:00 p.m. - 9:00 p.m.

Saturday

7:00 a.m. - 12:00 noon

E-mail

[email protected]

Spare parts Tel.

+49 (0) 7581 / 2008-353

E-mail

[email protected]

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5

2

Safety

2.1

Safety instruction labels

DANGER Identifies a high-risk danger that leads to death or serious injury if it is not avoided.

WARNING Identifies a medium-risk danger that can lead to death or serious injury if it is not avoided.

CAUTION Identifies a low-risk danger that can lead to minor or moderate injury if it is not avoided.

NOTICE Identifies a danger that can lead to property damage if not avoided.

2.2

Personnel qualification and training Operation, maintenance, inspection and installation personnel must have the appropriate qualifications for each of the described tasks.

2.3

Changes from the original status Only those accessories and spare parts approved by the manufacturer are permissible. If spare parts and accessories are independently modified or spare parts and accessories are used that are not approved, proper operation is not guaranteed.

2.4

Dangers resulting from nonobservance of safety instructions Ignoring safety instructions can pose a danger to personnel, the environment and machinery. Hazard examples: Failure of important machine functions. Danger to persons due to electrical, mechanical, thermal and chemical hazards. Danger to the environment due to the leakage of hazardous substances.

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3

Description of machine and functions

3.1

Normal use Delivery of homogeneous and heterogeneous fluids in pipes. Delivery of low-viscosity and high-viscosity fluids as well as lumpy fluids within the operating parameters individually specified for each pump. If this pump is integrated into or fitted to a machine or system, commissioning is prohibited until it has been established that the machine or system complies with the provisions of EU directive 2006/42/EC.

3.2

Improper use Any and all operations not in compliance with the individually specified operating parameters. Delivery of combustible fluids. Operation in areas posing a danger of explosion. Delivery of fluids not listed in the order confirmation.

3.3

Application area Stand-alone pump for dry-mount applications. Continuous and gentle delivery of fluids. KNOLL progressive cavity pumps are designed and produced in line with the latest standards in accordance with a certified quality assurance system based on DIN EN ISO 9001:2008. Since pumps are mechanical devices, they experience normal mechanical wear. Under high stress conditions or toward the end of the product's life, pumps can fail during operation. When pumps are used in sensitive areas of production requiring strict hygiene such as food production, users must use the latest technologies and configure the production system to immediately identify product contamination by pump parts and prevent subsequent damage.

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7

3.4

Layout

Fig. 3.4.1

3.5

A

Drive

E

Stator

B

Bearing housing

F

Rotor

C

Pump housing

G

Pressure connection (discharge)

D

Joint

H

Foot

Mode of operation Together, the rotor and stator create cavities or chambers. As the rotating units revolves, the medium within these cavities is continuously transported undamaged in the direction of delivery. The delivery rate depends on the rotational speed and the size of the drive unit. The length of the pump assembly determines the max. possible delivery pressure (number of closed cavities).

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3.6

Type plate A

Type

B

Order number and order item

C

Customer reference number

D

Serial number and year of manufacture

KNOLL Maschinenbau GmbH Schwarzachstraße 20 Fon +49 (0)7581/20 08-0 D-88348 Bad Saulgau Fax +49 (0)75 81/20 08-151 [email protected]

Typ Type

Auftrags-Nr. Order no.

K. Ref.-Nr. K. Ref. no.

Serien-Nr. / Baujahr Serial no.

/ Year of constr.

A B C D

Fig. 3.6.1

To order the correct spare parts, all of the information on the type plate are necessary. If the pump will be used in a harsh environment, it is recommendable to write down the information before installing the pump since legibility may decrease over time.

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3.7

Type code A

Designation

B

Model

C

Configuration

D

Pump assembly size

E

Pressure stage

MX 50R-##/##

A B C D E

MX 50S-15/20

Fig. 3.7.1

Type

MX 50R

Configur Hopper version with cleaning ation port

Fig. 3.7.2

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3.8

Technical data Individual operating parameters Individual operating parameters are designated for specific operating ranges for each KNOLL progressing cavity pump. The operating parameters are listed in the order confirmation. The optimum performance and wear is achieved when the pump operates within these parameters. If the pump operates outside of the specified parameters, wear increases which reduces the life of the pump. Furthermore, the pump may become damaged.

Maximum performance data The ratings depend on various factors such as temperature, viscosity and rotational speed, as well as the pumping medium and the model. The following values are maximum individual values and may not be reached in combination with the other values. The exact performance data are contained in the order confirmation.

3.9

Maximum pressure

up to 60 bar

Delivery rate

500 to 100,000 l/h

Viscosity

up to 200,000 mPa

Temperature

-30 °C to 140 °C

Free sphere passage

up to 76 mm

Noise emission data For systems produced by KNOLL Maschinenbau GmbH, a sound pressure level at the workplace (sound pressure level at the measurement surface) of Lpa =< 78 dB(A) is specified. This is defined as an energy-equivalent A-rated total noise level determined according to DIN 45635 Part 1 Class 2 with the enveloping surface method. Unfavorable environmental conditions and flow noise can require additional sound protection measures.

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11

4

Transport and storage DANGER Suspended loads Risk of injury from falling parts. Do not stand beneath suspended loads.

4.1

Transport Transport only by authorized personnel with certified qualifications. Ensure that the lifting gear has a sufficient load capacity. See order confirmation for the lifting weight. Always inspect the lifting gear prior to use. If damage from transportation is noted, do not alter the product or packaging. Report damage to transport company. A

Lifting gear

B

Transport sling

C

Pump

A

B

C

Fig. 4.1.1

12

⇨

Loose parts have been removed.

⇨

The residual medium has been properly disposed.

1.

Wrap the transport sling around the pump with slip. Use the transport sling on the pump drive if necessary.

➢

The weight is evenly distributed.

➢

The transport sling does not exert any pressure on attached components.

2.

Attach transport sling to lifting gear.

➢

The pump may now be transported.

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4.2

Storage Pumps that have already been filled or operated need to be drained and cleaned before being stored. Protect the pump from impact. Protect the pump against moisture, frost and heat. Protect pump against dust, dirt, UV radiation (sunlight) and other potentially harmful external influences. To preserve the pump, only use lubricating medium which does not become sticky over time. When storing elastomers, observe DIN7716.

Storage time up to 8 weeks ⇨

The pump is completely drained.

⇨

The pump has been cleaned [➙ 22].

1.

Rinse the pump.

2.

Run a lubricating, non-adhesive medium through the pump for a short time.

➢

The pump is preserved.

Storage time for more than 8 weeks ⇨

The pump is completely drained.

⇨

The pump has been cleaned [➙ 22].

1.

Rinse the pump.

2.

Disassemble the rotor and stator.

3.

Clean and preserve the pump parts.

4.

Store the pump parts dry, in the dark, and protected from dust.

5.

Make sure that there is no pressure on elastomer materials.

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13

5

Setup and installation DANGER Electricity Risk of injury from electric shock. Only qualified electricians may work on the electrical equipment.

WARNING Missing finger guard Risk of crushing or severing limbs. The infeed of progressing cavity pumps must be protected by a guard. Do not operate the pump without an appropriate finger guard.

CAUTION Containers and components that tip over Risk of injury from toppling parts. Secure pump with fasteners prior to commissioning. Check the stability of the entire machine.

CAUTION Rotating parts Risk of crushing or severing limbs. Do not reach into intake, discharge or assembly openings.

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5.1

Setup A

Pipework (discharge end) *

B

Infeed guard *

B

* To be provided by customer (not included in delivery) A

Fig. 5.1.1 1.

Remove all packaging material and dispose of it in an environmentally responsible manner.

2.

Use the mounting bolts and pressure port foot to install the pump on a pedestal or solid surface.

3.

Lock the mobile pump with the handbrake (optional).

Provide sufficient clearance (min. 350 mm before and after the pump) for servicing and sufficient drive motor ventilation.

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5.2

Installation Pipework (by the customer) Secure pipework directly upstream of the pump. Avoid unnecessary changes in direction and pipe cross-section. Do not select pipes with a nominal size that is smaller than the pump's nominal pipe size. Clean all piping elements and fittings; remove any burrs and welding beads. Flange gaskets should not protrude inwards. Use shut-off devices to make assembly / disassembly less complicated. Always make sure that any piping installed by the customer does not leak. 1.

Tightly connect piping accessories to the pump intake and pressure side ensuring that the pressure remains stable.

➢

The maximum force and torque correspond to the following table.

2.

Install the necessary accessories (see the relevant information in the order confirmation).

3.

Supply optional accessories (cleaning connection supply, heating jacket, shaft seal supply system).

4.

Voltage and frequency of the power supply.

5.

Connect power to the drive.

6.

Check the direction of rotation. [➙ 18]

Maximum force and torque The maximum permissible mechanical stress of the connections and pipework on other parts depends on the nominal diameter of the pipework. Neither the individual forces (Fx, Fy, Fz) and torques (Mx, My, Mz) as well as the overall force and torque may be exceeded. Overall force = root of (Fx2 + Fy2 + Fz2) Overall torque = root of (Mx2 + My2 + Mz2)

16

Nominal diameter Force (Fxyz)

Overall force

Torque (Mxyz)

Overall torque

25 mm

63 N

90 N

28 Nm

41 Nm

40 mm

85 N

120 N

38 Nm

56 Nm

50 mm

98 N

140 N

48 Nm

70 Nm

80 mm

141 N

200 N

71 Nm

105 Nm

100 mm

168 N

240 N

86 Nm

128 Nm

125 mm

203 N

290 N

108 Nm

160 Nm

150 mm

240 N

340 N

128 Nm

188 Nm

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6

Start-up DANGER Electricity Risk of injury from electric shock. Only qualified electricians may work on the electrical equipment.

CAUTION Hot surface Risk of burns. Note the product temperature. Allow pump to cool. Wear personal protective gear.

CAUTION Containers and components that tip over Risk of injury from toppling parts. Secure pump with fasteners prior to commissioning. Check the stability of the entire machine.

CAUTION High pressure If the pressure line is closed and the pump is operating, the pressure generated in the system may exceed permitted levels. Make sure that the shut-off devices in the high pressure line remain open during operation.

NOTICE Dry run or overpressure Pump damage. Before startup, fill the pump to prevent it from running dry. Check the direction of rotation. Protect pump against overpressure and dry running.

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6.1

Before startup Given the different chemical and physical properties of the elastomers which are used, make sure that only approved media and cleaners are used. Installed pumps should be switched on and off briefly once a week to ensure their operability. Never operate the pump dry.

6.2

⇨

Pipework connected to the pump.

⇨

Required accessories installed according to the order confirmation.

⇨

Optional accessory installed.

⇨

The drive is electrically connected.

⇨

The direction of rotation corresponds to the direction of rotation arrow [➙ 18].

1.

Check attached lines for leaks.

2.

Fully open stop valves / gate valves in the high pressure line.

3.

Close all tensioning mechanisms.

4.

Fill supply tanks and pump with the fluid to be conveyed.

➢

The pump is ready to use.

Checking the direction of rotation. A

Assembly opening with cover

B

Recess for visual inspection (KNOLL logo)

C

Direction of rotation arrow

D

Cover mounting screw

A B

C A B

D

Fig. 6.2.1

18

1.

Turn on the pump for no more than 1 second at a low speed (less than 100 rpm).

2.

Check the direction of rotation of the driveshaft through the openings in splash guard.

3.

If the direction of rotation does not correspond to the direction of rotation arrow, check the electrical connection and change it.

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6.3

Switching on ⇨

The drive is electrically connected.

⇨

The direction of rotation corresponds to the direction of rotation arrow [➙ 18].

⇨

Tanks are filled with a sufficient quantity of fluid.

1.

Prevent entry of air into the system.

2.

Fully open the shut-off valves / slide valves in the pressure line and suction line.

3.

Switch on the drive motor.

During operation, monitor for faults (see Fault table [➙ 48]).

6.4

Switching off 1.

Switch off the drive motor and check that the fluid discharges smoothly.

2.

If a non-return valve is not installed, close the installed stop valves once the rotor has come to a stop.

If the pump is stored for more than 8 weeks, see section Storage [➙ 13].

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19

6.5

Checks during operation Installed pumps should be switched on and off briefly once a week to ensure their operability. Regularly perform servicing tasks (see Maintenance [➙ 50]).

1.

Make sure that the pump runs smoothly and does not vibrate.

2.

Monitor for faults (see Fault table [➙ 48]).

3.

If excess liquid drains from the leakage hole in the bearing bracket, check the shaft seal.

Shaft seal When operating properly, shaft seals exhibit slight or no visible (vapor) leakage. Is leakage occurs, Replacing the shaft seal [➙ 37]. Axial face seal The axial face seals are maintenance-free. When operating properly, axial face seals exhibit only minimal or no visible leakage (vapor). If leaks appear, the axial face seal must be replaced in its entirety [➙ 32]. Packing gland If excess liquid drains from the leakage hole in the bearing bracket, Adjusting the gland packing [➙ 41]. If there is too much leakage and the packing can no longer be readjusted, Replace packing gland [➙ 40].

20

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7

Repair DANGER Electricity Risk of injury from electric shock. Only qualified electricians may work on the electrical equipment.

CAUTION Automatic start-up Risk of injury from rotating parts. Before beginning maintenance work, switch off the master switch and secure against unintentional startup.

CAUTION Hot surface Risk of burns. Note the product temperature. Allow pump to cool. Wear personal protective gear.

CAUTION Hazardous pumping medium Health risk. Avoid any skin contact with the pumping medium. Follow the safety instructions of the medium manufacturer. Wear personal protective gear.

NOTICE Improper maintenance Pump damage. Before beginning maintenance work, drain the pump and clean it. Use only genuine OEM spare parts and accessories approved by the manufacturer. Modification and changes to the pump are only permissible following consultation with KNOLL. Thoroughly clean the pump, it's and enclose the safety data sheet for the fluid.

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21

7.1

Cleaning the pump Regularly clean the pump. The frequency of cleaning depends upon the delivered fluid and additional process parameters. Before service and maintenance work, thoroughly clean the pump. Only use chemical cleansers after talking with KNOLL. Do not use chemical cleansers or jet water for external cleaning. Do not shoot a jet of water directly onto the shaft seal. Make sure that environmentally hazardous substances do not escape. Follow the instructions of the fluid manufacturer. Dispose of fluid in the proper manner.

7.2

Loosening the release shaft A special release shaft enables service and maintenance work to be performed directly on components of MX pumps.

A

Assembly opening with cover

B

Roundhead bolt

A

(Release shaft retainer) C

Cover mounting screw

D

Driveshaft

A

C D

B

Fig. 7.2.1

22

⇨

Electrical connection has been disconnected.

⇨

Pressure and suction lines disconnected.

⇨

Pump is depressurized.

1.

Only unscrew the cover mounting screw until the cover can be rotated manually.

➢

The cover mounting screw is not completely unscrewed.

2.

Rotate the cover until the opening appears.

3.

Remove both roundhead bolts. If necessary, loosen driveshaft by rotating it.

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7.3

Pump housing

7.3.1

Removing the pump housing A

Pressure connection (discharge)

B

Mounting screws

C

Joint with feed screw

D

Pump assembly

E

Bearing housing

F

Pump housing

B B F

B E

C B A

D

Fig. 7.3.1.1 ⇨

The release shaft is released [➙ 22].

1.

Loosen and remove mounting screws between pump housing and bearing housing.

2.

Loosen and remove mounting screws between the pressure port foot and pedestal.

3.

Carefully remove the pump housing together with pump assembly from the bearing housing.

4.

Secure the release shaft to prevent it from falling.

5.

Place the pump housing together with the pump assembly on a clean working surface.

BA_MX50R_262397_englisch_1

23

7.3.2

Installing the pump housing 1.

Insert the pump assembly with pump housing into the bearing housing.

2.

Align openings in release shaft and driveshaft.

3.

Screw in the roundhead bolts in on both sides.

4.

Join pump housing and bearing housing with mounting bolts.

5.

Secure pressure port foot of pump assembly to pedestal with mounting bolts.

6.

Tighten the roundhead bolts on both sides and tighten.

7.

Rotate cover until the assembly opening is closed.

8.

Screw in mounting screw for securing the cover.

Roundhead bolt tightening torque: 135 Nm. Secure roundhead bolts with Loctite 222 or Weicon AN302-22.

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7.4

Pump assembly

7.4.1

Removing the pump assembly with joint and release shaft A

Pressure connection (discharge)

B

Mounting screw Pressure port foot/pedestal

C

Mounting screw Pump assembly/pump housing

D

Pump assembly

E

Joint

F

Pump housing

G

O-ring

H

Stator module ring

J

Mounting screw Pump assembly/pressure connection (discharge) Fig. 7.4.1.1

⇨

The release shaft is released [➙ 22].

1.

Remove mounting screws between the pump assembly and pump housing.

2.

Remove mounting screws between the pressure port foot and pedestal.

3.

Remove the pump assembly together with joint and release shaft from the pump housing completely.

4.

Remove mounting screws between the pump assembly and pressure connection.

5.

Secure the joint and release shaft to prevent it from falling.

6.

Remove the pressure connection with the stator module ring from the pump assembly.

7.

To dismantle further, Clamp pump assembly in mounting plate [➙ 26].

BA_MX50R_262397_englisch_1

25

7.4.2

Clamp pump assembly in mounting plate A

Pump assembly with joint and release shaft

B

Release shaft

C

Joint

D

Stator

E

Block stop

F

Mounting plate

B

C A

(see Assembly tools [➙ 47]) G

Mounting screw

H

Stator clamping ring

J

Round locking ring

K

Stator module ring

G D H E F

J K

Fig. 7.4.2.1

26

⇨

Pump assembly with joint and release shaft removed [➙ 25].

1.

Insert the block stop in the mounting plate.

2.

Mount the stator module ring.

3.

Insert the pump assembly into the mounting plate and clamp.

BA_MX50R_262397_englisch_1

7.4.3

Disassembling the release shaft A

Release shaft

B

Retaining sleeve

C

Joint

A

D

Open-end wrench

B

(see Assembly tools [➙ 47])

C

E

O-ring

F

Roundhead bolt

D A E B E F C

Fig. 7.4.3.1 ⇨

Pump assembly with joint and release shaft removed [➙ 25].

⇨

Pump assembly is clamped in mounting plate [➙ 26].

1.

Use the open-end wrench to loosen the retaining sleeve.

2.

Slide the retaining sleeve upward.

3.

Loosen and remove both roundhead screws.

4.

Remove the release shaft.

BA_MX50R_262397_englisch_1

27

7.4.4

Removing the joint A

Joint

B

Retaining sleeve

C

Roundhead bolt

D

Open-end wrench (see Assembly tools [➙ 47])

A B D C

Fig. 7.4.4.1

28

⇨

Pump assembly with joint and release shaft removed [➙ 25].

⇨

Pump assembly is clamped in mounting plate [➙ 26].

1.

Use the open-end wrench to loosen the retaining sleeve.

➢

Retaining sleeve with left-hand thread is identified with "LH" on the rotor side.

2.

Slide the retaining sleeve downward until the roundhead bolts are accessible.

3.

Loosen both roundhead bolts until the joint can be removed together with the release shaft.

4.

Remove joint.

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7.4.5

Removing the rotor Only remove the rotor for single or two-stage pump assemblies. Pump assemblies that have three or more stages should be completely returned to KNOLL for maintenance. Request a return slip and clearance certificate. A

Torsion tube with rotor adapter

B

Rotor

C

Roundhead bolt

D

Stator

A

B C

D

Fig. 7.4.5.1

7.4.6

⇨

Joint is removed [➙ 28].

1.

Place the rotor adapter on the rotor.

2.

Fasten the rotor adapter to the rotor with roundhead bolts.

3.

Insert the torsion tube into the rotor adapter.

4.

Remove rotor from stator by unscrewing it counterclockwise with the aid of the torsion tube.

Replacing the stator ⇨

Rotor is removed [➙ 29].

1.

Note the installation position of stator entry taper.

2.

Remove the stator from the mounting plate.

3.

Remove the round locking ring, stator module ring and stator clamping ring, and install them on the new stator.

4.

Make sure that the block stop is inserted in the mounting plate.

5.

Clamp the new stator in the mounting plate.

➢

The installation position of the stator entry taper is the same as the installation position of the old stator.

BA_MX50R_262397_englisch_1

29

7.4.7

Installing the rotor A

Torsion tube with rotor adapter

B

Roundhead bolt

C

Rotor

D

Stator

E

Bottom edge of rotor

F

Installation plate with block stop

Fig. 7.4.7.1

30

⇨

The stator is clamped on the mounting plate.

1.

Place the rotor adapter on the rotor.

2.

Fasten the rotor adapter to the rotor with roundhead bolts.

3.

Insert the torsion tube into the rotor adapter.

4.

Screw the rotor all the way into stator clockwise with the aid of the torsion tube.

➢

The rotor sits on the block stop.

5.

Loosen the roundhead bolts.

6.

Lift the rotor adapter off of the rotor.

BA_MX50R_262397_englisch_1

7.4.8

Installing the pump assembly with joint and release shaft A

Stator with rotor

B

Rotor head

C

Pump assembly with collar and release shaft

D

Retaining sleeve

E

O-ring

F

Roundhead bolt

G

Surface for open-end wrench

C

E D

F

D

B

G A

Fig. 7.4.8.1 ⇨

Rotor is installed [➙ 30].

1.

Place the retaining sleeve on the rotor head.

2.

Place a new O-ring on the joint.

3.

Place the joint and release shaft on the rotor.

➢

The bores in the joint are flush with the bore in rotor.

4.

Screw in all roundhead bolts.

5.

Slide retaining sleeve over the O-ring and tighten with the open-and wrench.

➢

Retaining sleeve with left-hand thread is identified with "LH" on the rotor side.

6.

Remove the pump assembly from the mounting plate.

➢

The pump assembly with joint and release shaft can be installed in the pump housing.

Roundhead bolt tightening torque: 135 Nm. Secure roundhead bolts with Loctite 222 or Weicon AN302-22.

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31

7.5

Shaft seal As needed, different models of the shaft seal can be installed. For the model of the shaft seal, see order confirmation.

NOTICE Improper removal/installation Damage to components. Take extra care when installing the axial face seals and ensure maximum cleanliness throughout the procedure. Do not tilt the axial face seal and mechanical seal seat. Do not place the sealing elements on sliding surfaces. Never touch sliding surfaces with bare hands. Elastomers can be moistened with appropriate installation agent for easier installation. Follow the installation instructions of the manufacturer of the axial face seal.

32

BA_MX50R_262397_englisch_1

7.5.1

Replace product-side axial face seal Rotating unit for MXEB / MXHS EHEDG / MXHD A

Rotating unit for the axial face seal

B

Face pin spanner wrench

C

Mechanical seal seat with backing ring

D

Bearing housing

E

Pin

F

Driveshaft

Fig. 7.5.1.1 ⇨

Pump housing is removed [➙ 23].

1.

Place face pin spanner wrench into opening of the rotating element of the axial face seal.

2.

Insert pin into the hole in the driveshaft and hold it in place securely.

➢

The driveshaft is fixed.

3.

Using the face pin spanner wrench, loosen the rotating unit/spacer ring (MXEB).

4.

Pull rotating unit off the driveshaft.

The new rotating unit is installed in reverse sequence. If necessary, replace the stationary unit beforehand.

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33

Stationary unit for the MXEB, MXHS EHEDG A

Mechanical seal seat

B

Driveshaft

C

Bearing housing

D

GRD (axial face seal carrier) backing ring

B

C

A

D

A

Fig. 7.5.1.2

34

1.

Pull axial face seal carrier off the driveshaft and place it on a clean surface.

2.

Push the axial face seal backing ring out of the axial face seal carrier.

3.

Carefully press in the new backing ring.

4.

Insert the axial face seal carrier into the bearing housing.

BA_MX50R_262397_englisch_1

Stationary unit for the MXHS, MXHD A

Mechanical seal seat

B

Driveshaft

C

Bearing housing

D

Circlip

E

Washer

F

O-ring

G

GRD (axial face seal carrier) backing ring

H

O-ring

J

Mechanical seal seat O-ring (optional)

C

B A

A J

H

G

F

E

D

Fig. 7.5.1.3 1.

Pull axial face seal carrier off the driveshaft and place it on a clean surface.

2.

Release the circlip.

3.

Remove the spacer disk, O-ring and axial face seal backing ring out of the axial face seal carrier.

4.

Carefully press in the new backing ring with the spacer disk and new O-ring.

5.

Insert the axial face seal carrier (with new O-ring) into the bearing housing.

6.

Fix the mechanical seal seat with the circlip.

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35

7.5.2

Replacing the axial face seal A

Circlip

B

Washer

C

Axial face seal

D

O-ring

E

GRD (axial face seal carrier) backing ring

F

Mechanical seal seat

G

Driveshaft

H

Bearing housing

J

Circlip

G

H

F E A B

C

D

J

E

F

Fig. 7.5.2.1

36

⇨

Product-side axial face seal is removed [➙ 33].

⇨

Hose bushings are removed.

1.

Remove circlip and washer.

2.

Pull axial face seal off the driveshaft and place it on a clean surface.

3.

Pull off axial face seal carrier over the driveshaft.

4.

Push the axial face seal backing ring out of the axial face seal carrier.

5.

Carefully press in the new backing ring.

6.

Replace O-ring.

7.

Place axial face seal carrier on the driveshaft.

8.

Place the mounting tool on the driveshaft thread, and mount the axial face seal on the driveshaft.

9.

Mount the circlip and washer.

BA_MX50R_262397_englisch_1

7.5.3

Replacing the shaft seal As needed, the different models and numbers of shaft seals can be installed. See order confirmation for model of seal.

A

Shaft guard sleeve

B

Seal housing

C

Rotary shaft seal

D

Flushing ring for quench supply (optional)

E

Gland follower

F

Gland follower bolt

G

Driveshaft

H

Bearing housing

J

O-ring

K

Face pin spanner wrench

H C D G

J

C E

B

F J A K G

Fig. 7.5.3.1 ⇨

Pump housing is removed [➙ 23].

⇨

The hose bushings are removed in the design with a quench connection.

1.

Loosen and remove shaft guard sleeve.

2.

Pull off the seal housing.

3.

Remove bolt from the gland follower and note the installation position of the shaft seals.

4.

Remove gland follower and shaft seals from the seal housing.

5.

Carefully clean the seal housing and follower.

6.

Insert new shaft seals.

➢

The installation position corresponds with the previously noted position.

7.

Reattach the gland follower.

8.

Replace O-ring.

9.

Replace the shaft guard sleeve if worn and screw on.

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37

Rotary shaft seal installation position Incorrect installation position of the rotary shaft seals will result in leakage. Note the installation position of the shaft seals. Make sure that none of the parts have internal or external damage. Avoid damaging the sealing lips. Use assembly tools. A

Product-side tandem installation position (on the right in the illustration)

B

Back-to-back orientation

C

Atmosphere-side tandem installation position (on the left in the illustration)

A

B

C

Fig. 7.5.3.2

38

BA_MX50R_262397_englisch_1

7.5.4

Dismantling the packing gland A

O-ring

B

Packing gland Holder for packing gland rings

C

Packing gland ring

D

Gland follower

E

Shaft guard sleeve

F

Gland follower bolt

G

Face pin spanner wrench

A B

C

D

E

F

G

Fig. 7.5.4.1 ⇨

Pump housing is removed [➙ 23].

⇨

The hose bushings are removed in the design with a quench connection.

1.

Loosen bolts in the packing gland.

2.

Remove shaft guard sleeve.

3.

Remove the gland.

BA_MX50R_262397_englisch_1

39

7.5.5

Replace packing gland A

Hexagon nut

B

Washer

C

Gland follower

D

Packing gland rings

E

Flushing ring for quench supply (optional)

F

Packing gland

G

Break in packing gland ring

H

Connection for quench (optional)

Fig. 7.5.5.1

7.5.6

40

1.

Remove hexagon nuts, washer and gland follower.

2.

Remove old packing gland rings and flushing ring (optional) from the housing.

3.

Carefully clean the gland housing and follower.

4.

Insert new packing gland rings and flushing ring (optional) into the gland housing.

➢

The breaks in the rings are offset 90° with respect to one another.

5.

Insert gland follower into the gland housing.

6.

Slightly tighten hexagon nuts by hand.

Installing the packing gland 1.

Slide packing gland housing all the way into bearing housing.

➢

The seal housing abuts the bearing bracket.

➢

The hexagon nuts for the gland follower are accessible inside the guard.

2.

Replace the shaft guard sleeve if worn and install it on the driveshaft.

3.

Use face pin spanner wrench to tighten the shaft guard sleeve.

BA_MX50R_262397_englisch_1

7.5.7

Adjusting the gland packing The sealing action of the gland packing is achieved by pressing the packing gland rings together. Optimum adjustment is achieved when only an occasional drop of the substance being conveyed escapes from the weep hole. Incorrect adjustment of the gland packing can result in increased leakage. Excessive compression prevents self-lubrication of the gland packing. A compressed packing can heat up and start to burn. This causes increased wear. If there is too much leakage and the packing can no longer be readjusted, Replace packing gland [➙ 40]. A

Packing gland housing

B

Hexagon nut

C

Weep hole

Fig. 7.5.7.1 ⇨

Electrical connection has been disconnected.

⇨

Pump is depressurized.

1.

Unscrew the cover mounting screw until the cover can be rotated manually.

2.

Rotate the cover until the opening appears.

3.

Tighten the hexagon nuts on both sides in 90° increments.

➢

The rings are pressed together.

4.

Rotate cover until the assembly opening is closed.

5.

Screw in mounting screw for securing the cover.

6.

Start the pump and monitor the liquid discharge.

7.

Repeat the procedure until a drop of liquid appears only occasionally.

BA_MX50R_262397_englisch_1

41

7.6

Drive

7.6.1

Removing the drive A

Pump

B

Drive/pump mounting bolt

C

Drive

D

Feather key

Fig. 7.6.1.1

7.6.2

42

⇨

Electrical connection has been disconnected.

1.

Secure the drive with appropriate tools.

➢

The drive cannot fall.

➢

Avoid stress while removing the mounting screws.

2.

Remove mounting screws.

3.

Carefully pull off the drive.

Installing the drive 1.

Rotate the driveshaft in the drive until the feather key aligns with the keyway in the drive shaft.

➢

The holes in the drive flange are flush.

2.

Slide drive into the pump.

➢

The drive flange and pump flange are flush with each other.

3.

Using mounting bolts, fasten the drive flange and pump flange together securely.

4.

Connect power to the drive.

5.

Checking the direction of rotation. [➙ 18].

BA_MX50R_262397_englisch_1

8

Optional accessories

8.1

Cleaning connection A

Pressure connection (discharge)

B

Pump assembly

C

Suction connection (intake)

D

Cleaning port

E

External pump

C

B A

D

M

E Fig. 8.1.1 Cleaning of production system without dismantling the pump At low operation speeds, the flow speed in the pump housing sufficient for cleaning is frequently not reached. In such cases, the pumps can optionally be equipped with a cleaning port. The required flow rate (> 1.5 m/s) is achieved through use of an additional external pump. The cleaning cycle depends on the level of soiling and fluid being conveyed. Cleaning can be performed several times daily or only when the fluid is changed. In the cleaning process, the cleaning fluid passes through the suction connection into the body of the pump. This ensures that the rotating parts as well as the axial face seal are cleaned completely. Most of the cleaning fluid exits the pump housing through the flushing connection. Any remaining cleaning fluid enters the pump assembly. To operate the pump using a CIP process (cleaning in place) or SIP process (sterilization in place with hot steam), a corresponding pump design must be arranged with KNOLL. Rinse the pump of water after a CIP cleaning. To prevent a vacuum from arising after SIP cleaning, ventilate the pump when cooling.

BA_MX50R_262397_englisch_1

43

8.2

Heating jacket A

Return line connection

B

Pump assembly heating jacket A

(removable) C

Pump housing heating jacket

A

C

B

(not removable) D

Feed line connection

D

Fig. 8.2.1 Connect to the supply line to the heating jacket horizontally for an air-free and hence more effective heat transfer medium connection. Connect the return line from the heating jacket at the top most position. Observe operating conditions according to the order confirmation.

44

BA_MX50R_262397_englisch_1

8.2.1

Removing the heating jacket A

Pressure connection (discharge)

B

Heating jacket

C

Round locking ring

D

Thrust ring

E

Stator clamping ring

F

O-ring

Fig. 8.2.1.1 ⇨

The heat transfer medium supply is shut off.

1.

Remove connections from the heating jacket.

2.

Remove the pressure port foot and stator module ring.

3.

Support the pump with appropriate aids.

4.

Slide stator clamping ring together with thrust ring towards the drive.

➢

The round locking ring is exposed.

5.

Remove round locking ring.

6.

Slide stator clamping ring together with thrust ring out through pressure connection (discharge).

7.

Remove heating jacket.

BA_MX50R_262397_englisch_1

45

8.3

Sensors

8.3.1

Installing the diaphragm seal Diaphragm seal for shutting off the pump when the maximum operating temperature is reached

Fig. 8.3.1.1

8.3.2

⇨

Follow the manufacturer's operating instructions.

1.

Install the sensor in the pressure line.

2.

Electrically connect the sensor.

3.

Wire the switching output as the opener.

4.

Set the start signal to the maximum operating pressure.

Installing temperature sensor Temperature sensor for shutting off the pump when then maximum operating temperature is reached

Fig. 8.3.2.1

46

⇨

Follow the manufacturer's operating instructions.

1.

Install the sensor on the stator housing.

2.

Electrically connect the sensor.

3.

Wire the switching output as the opener.

4.

Set the switching threshold to 2 - 5 °K above the maximum operating temperature.

BA_MX50R_262397_englisch_1

8.4

Assembly tools Nonstandard assembly tools for maintenance are available from KNOLL (requires knowledge of pump size). Refer to information on type plate. Description

Ident. No.

Mounting plate

152078

Open-end wrench - 109 mm

180723

Open-end wrench - 104 mm

180726

Face pin spanner wrench

182473

BA_MX50R_262397_englisch_1

47

9

Eliminating system faults If problems arise, immediately turn off the pumps to prevent irreparable damage or keep the fluid from being contaminated. Determine the cause of the fault using the fault table and eliminate it. Only starts the pump after the problem has been eliminated.

9.1

Fault table Fault:

Possible cause:

Remedy:

Pump does not start.

No power supply.

Check power supply.

Drive motor defective.

Check drive motor.

Motor protection switch has tripped.

Check electrical cables and drive motor for short-circuits.

Blocked by foreign objects.

Remove foreign objects. Check the pump for damage.

48

Deposits after pump has been idle. Fluid hardens (depending on temperature or chemical composition).

Clean pump immediately after use.

Solids content too high.

Check pumping conditions; change configuration if necessary.

Stator swollen from excessive temperature.

Check the temperature of the fluid.

Stator swollen from chemical influences.

Verify the resistance of the stator elastomer to the fluid.

System pressure too high.

Compare the nominal pressure of the pump with system conditions. Change configuration.

Long pump downtime.

Disassemble the pump and reassemble with lubricant.

BA_MX50R_262397_englisch_1

Fault:

Possible cause:

Remedy:

Delivery rate decreases or required rate is no longer achieved.

System pressure too high.

Compare the nominal pressure of the pump with system conditions, adapt configuration.

Air bubbles in the fluid.

Prevent the ingress of air.

Stator and/or rotor worn.

Replace.

Seals defective.

Verify that fluid is being supplied, check seals, replace seals.

Incorrect direction of rotation.

Change direction of rotation; observe direction arrow.

Dry run occurred, stator may be damaged.

Replace stator, verify that the dry-run protection device is connected correctly.

Joints worn.

Replace joints.

Cavitation.

Check configuration. Select lower rotational speed. Increase pipe size (cross section). Check configuration. Decrease fluid temperature.

Drive motor defective.

Check drive motor; replace if necessary.

Excessive pressure.

Use pressure.

Stator swollen from excessive temperature.

Check the temperature of the fluid.

Stator swollen from chemical influences.

Verify the resistance of the stator elastomer to the fluid.

Wrong type of connection.

Compare the connection type with the information on the order confirmation.

Insufficient lubrication from unfavorable operating conditions.

Slightly change the rotational speed or pressure.

Pump does not draw in.

Loud pump noises.

Motor protection switch trips.

Squeaky pump.

BA_MX50R_262397_englisch_1

49

10

Maintenance

10.1

Maintenance intervals Maximum maintenance intervals during normal operation: Daily After 500 operating hours (at least monthly) After 1500 operating hours (at least quarterly) After 3000 operating hours (at least semiannually) After 6000 operating hours (at least annually) When the pump is operated at the threshold, the intervals should be appropriately shortened.

10.2

Daily Component

Action

Comment

Powertrain

Check for wear and damage.

Rotor and stator

Check for wear and damage.

A decrease in delivery rate indicates pump wear.

Sleeve

Visual inspection

Replace in the case of damage.

Shaft seal

Visual inspection for leakage

Replace the shaft seal in case of increased leakage.

Pump

Visual inspection

Shaft seal with packing gland The packing gland can be adjusted. If readjustment is not possible, replace the packing gland.

50

BA_MX50R_262397_englisch_1

10.3

10.4

After 1500 operating hours Component

Action

Protective devices

Check for proper operation; clean.

Drive motor

Clean cooling air openings and housing.

Comment

Clean components with dry compressed air.

After 3000 operating hours Component

Action

Drive motor

Refer to manufacturer's operating instructions.

Housing/pump body

Check for leaks, damage and corrosion.

BA_MX50R_262397_englisch_1

Comment

Make sure that environmentally hazardous substances do not escape.

51

11

Drawings

11.1

Replacement part drawing Given the many versions of the product and possible combinations, an individual replacement part drawing with a spare parts list is created and is separately available for customer documentation.

11.2

Spare-parts lists The following list contains the most important wearing parts that you should stock to ensure high pump availability and low MTTR values (mean time to repair) (DIN 24296 recommendation). The function numbers refer to the individual replacement part drawing with the replacement part list from the customer documentation.

To order the correct spare parts, all of the information on the type plate [➙ 9] are necessary. If incorrect information is supplied, we shall not assume liability for incorrect deliveries.

Function no.

Description

Comment

2001

Product-side axial face seal

2003

O-ring

2012

Packing gland ring/rotary shaft seal

Optional

2018

Shaft guard sleeve

Optional

2023

Atmosphere-side axial face seal

2024

Atmosphere-side axial face seal O-ring

3000

Joint with sleeve

3005

O-ring

3010

O-ring

5001

Stator

5002

Rotor

5006

O-ring

Optional

When stocking replacement parts, be aware of the general storage conditions for a last number parts.

52

BA_MX50R_262397_englisch_1

12

Disposing of the system

12.1

Disposal 1.

Remove all fluid and dispose of it in an environmentally responsible manner.

2.

Dispose of metal parts and electronic assemblies as scrap.

3.

Recycle plastic parts or dispose of them as residual waste material.

There must be no environmentally hazardous deposits adhering to the parts. Electronic assemblies and parts may not be disposed of as urban waste. Comply with worker safety and environmental protection regulations when working with hazardous fluids.

BA_MX50R_262397_englisch_1

53

13

EC Declaration of Conformity 2006/42/EC, Annex II Part 1 A The company KNOLL Maschinenbau GmbH Schwarzachstrasse 20 D-88348 Bad Saulgau, Germany declares hereby that the following product Progressing cavity pump Type

MX 50R

to which this Declaration refers conforms to the fundamental requirements according to the provisions of the EC Directive. 2006/42/EC

The following overriding harmonized standard was used to evaluate the products: DIN EN ISO 12100 DIN EN 809:2012-10

City/town:

D-88348 Bad Saulgau, Germany

Date:

2014-04-10

Jürgen Knoll

Nikolaus Harraßer

CTO

Individual responsible for documentation See above for address

54

BA_MX50R_262397_englisch_1

BA_MX50R_262397_englisch_1

55

KNOLL Maschinenbau GmbH Schwarzachstrasse 20 D-88348 Bad Saulgau Tel. + 49 (0) 7581/2008-0 Fax + 49 (0) 7581/2008-140 [email protected] www.knoll-mb.de