Professional Documents
Culture Documents
Alfa Laval Solidc Pump Instruction Manual Ese00797en
Alfa Laval Solidc Pump Instruction Manual Ese00797en
SolidC Pump
3008-0028
ESE00797-EN7 2016-10
Original manual
Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 6
3. Installation .............................................................................................. 7
3.1. Unpacking/delivery ............................................................................... 7
3.2. Installation ......................................................................................... 8
3.3. Pre-use check ..................................................................................... 9
3.4. Recycling information ............................................................................. 9
4. Operation ............................................................................................... 10
4.1. Operation/Control ................................................................................. 10
4.2. Trouble shooting .................................................................................. 12
4.3. Recommended cleaning ......................................................................... 13
5. Maintenance ........................................................................................... 14
5.1. General maintenance ............................................................................. 14
5.2. Cleaning Procedure ............................................................................... 15
5.3. Dismantling of pump/shaft seals ................................................................ 16
5.4. Assembly of pump/single shaft seal ............................................................ 18
5.5. Assembly of pump/flushed shaft seal ........................................................... 20
5.6. Adjustment of shaft ............................................................................... 22
3
1 EC Declaration of Conformity
+45 79 32 22 00
Phone No.
The person authorised to compile the technical file is the signer of this document
Kolding 2013-12-03
Place Date Signature
4
2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
Always read the manual before using the pump!
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the pump.
NOTE
Indicates important information to simplify or clarify procedures.
General warning:
Caustic agents:
5
2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
Always read the manual before using the pump!
Installation:
Always read the technical data thoroughly. (See chapter 6 Technical data) !
Always use a lifting crane when handling the pump.
Never start in the wrong direction of rotation with liquid in the pump.
Always have the pump electrically connected by authorised personnel. (See the motor instruction)
Operation:
Always read the technical data thoroughly. (See chapter 6 Technical data) !
Never touch the pump or the pipelines when pumping hot liquids or when sterilising.
Never run the pump with both the suction side and the pressure side blocked.
Never run the pump when partially installed or not completely assembled
Necessary precautions must be taken if leakage occurs as this can lead to hazardous situations
Maintenance:
Always read the technical data thoroughly. (See chapter 6 Technical data) !
Never service the pump when it is hot.
Never service the pump if pressurised.
Always use Alfa Laval genuine spare parts.
Transportation:
Transportation of the pump or the pump unit:
Never lift or elevate in any way other than described in this manual
Always drain the pump head and accessories of any liquid
Always ensure that no leakage of lubricants can occur
Always transport the pump in its upright position
Always ensure that the unit is securely fixed during transportation
Always use original packaging or similar during transportation
6
3 Installation
3.1 Unpacking/delivery
Step 2
Remove any packing materials from the inlet and the outlet.
Avoid damaging the inlet and the outlet.
Avoid damaging the connections for flushing liquid, if supplied.
TD 241-003/1
Step 3
Inspect the pump for visible transport damage.
TD 241-003/2
Step 4
Always remove the shroud, if fitted, before lifting the pump.
TD 241-004/1
7
3 Installation
Study the instructions carefully and pay special attention to the warnings! Always check the pump before operation.
- See pre-use check in section 3.3 Pre-use check, page 9
The large pump sizes are very heavy. Alfa Laval therefore recommends the use of a lifting crane when handling the pump.
3.2 Installation
Step 1 CAUTION
CAUTION
Always have the pump electrically connected by authorised The pump does not prevent back flow when
personnel. (see the motor instructions). intentionally or unintentionally stopped. If back flow
can cause any hazardous situations, precautions
NOTE must be taken e.g. check valve to be installed in the
In case of shaft seal leakage, the media will drip from the slot in system preventing above described.
the bottom of the adaptor. In case of shaft seal leakage, Alfa
Laval recommends placing a drip tray underneath the slot for
collecting the leakage.
Step 2
Ensure that there is sufficient clearance around the pump (min.
0.5 m)(1.64 ft).
NOTE!
US pumps have no shroud
TD 241-005/1
Inlet
TD 241-006
Step 4 Remember
1. Ensure that the pipelines are routed correctly. Seal rings!
2. Ensure that the connections are tight.
Few bends
TD 241-007
Correct!
8
3 Installation
Study the instructions carefully and pay special attention to the warnings!
SolidC comes with impeller screw as standard.
Check the direction of rotation of the impeller before operation.
- See the indication label on the pump.
Step 5
Avoid stressing the pump.
Pay special attention to:
- Vibrations
Avoid
- Thermal expansion of the tubes
- Excessive welding bending
- Overloading pipelines
TD 241-008/1
Correct
Never start in the wrong direction of rotation with liquid in the
pump.
1. Start and stop the motor momentarily
2. Ensure that the direction of rotation of the motor fan is
clockwise as viewed from the rear end of the motor. TD 241-013/1
• Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.
- Wood and cardboard boxes can be reused, recycled or used for energy recovery
- Plastics should be recycled or burnt at a licensed waste incineration plant
- Metal straps should be sent for material recycling
• Maintenance
- During maintenance, oil and wear parts in the machine are replaced
- All metal parts should be sent for material recycling
- Worn out or defective electronic parts should be sent to a licensed handler for material recycling
- Oil and all non-metal wear parts must be disposed of in accordance with local regulations
• Scrapping
- At end of use, the equipment must be recycled according to relevant, local regulations. Besides the equipment itself, any
hazardous residues from the process liquid must be considered and dealt with in a proper manner. When in doubt, or in the
absence of local regulations, please contact your local Alfa Laval sales company.
9
4 Operation
Study the instructions carefully and pay special attention to the warnings!
4.1 Operation/Control
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect
operation/control.
Never touch the pump or the pipelines when pumping hot liquids
or when sterilising.
TD 241-014
Never run the pump with both the suction side and the pressure
!
side blocked. See the
warning label!
TD 241-015
Step 4
CAUTION
The shaft seal must not run dry.
CAUTION
Never throttle the inlet side.
TD 241-075
Wrong
10
4 Operation
Study the instructions carefully and pay special attention to the warnings!
Step 5 Correct!
Free
Flushed shaft seal: outlet
1. Connect the inlet of the flushing liquid correctly.
2. Regulate the water supply correctly.
R1/8”
(BSP)
Step 6 Throttling!
Control:
Reduce the capacity and the power consumption by means of:
- Throttling the pressure side of the pump.
- Reducing the impeller diameter.
- Reducing the speed of the motor.
11
4 Operation
Pay attention to possible faults.
Study the instructions carefully.
NOTE!
Study the maintenance instructions carefully before replacing worn parts.
Cavitation:
- Damage - Low inlet pressure - Increase the inlet pressure
- Pressure reduction (sometimes to - High liquid temperature - Reduce the liquid temperature
zero)
- Increasing of the noise level - Reduce the pressure drop before the
pump
- Reduce speed
12
4 Operation
The pump is designed for cleaning in place (CIP). CIP = Cleaning In Place.
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic Soda.
HNO3 = Nitric acid.
TD 241-014/1
Step 3
!
Always rinse well with clean water after using a cleaning agent.
Water Cleaning agent
NOTE
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
13
5 Maintenance
Maintain the pump carefully. Study the instructions carefully and pay special attention to the warnings!
Always keep spare shaft seals and rubber seals in stock.
See separate motor instructions.
Check the pump for smooth operation after service.
Step 1
!
Always read the technical data thoroughly. (See chaper 6 Technical data)
NOTE
All scrap must be stored/discharged in accordance with current rules/directives.
!
Never service the pump when it is hot.
TD 241-014/1
Step 3
Atmospherie pressure
! required!
Never service the pump with pump if pressurised.
CAUTION
Fit the electrical connections correctly if they have been removed TD 241-018/1
CAUTION
Pay special attention to the warnings!
Step 4
Recommended spare parts:
Order service kits from the service kits list
(see chapter 7 Parts list and service kits).
Note:
If the pump is supplied with FEP O-rings, Alfa Laval recommends that the casing O-ring is replaced during pump maintenance.
14
5 Maintenance
Maintain the pump carefully. Study the instructions carefully and pay special attention to the warnings!
Always keep spare shaft seals and rubber seals in stock.
See separate motor instructions.
Check the pump for smooth operation after service.
Maintenance after leakage Replace at the end of the Replace when replacing the
(leakage normally starts slowly) day: Complete shaft seal shaft seal
Planned maintenance - Regular inspection for Replace when replacing the Yearly inspection is
leakage and smooth shaft seal recommended
operation - Replace complete bearing
- Keep a record of the pump if worn
- Use the statistics for - Ensure that the bearing is
inspection planning axially locked (See motor
instructions)
Replace after leakage:
Complete shaft seal
Pre-use check
CAUTION!
Fit the electrical connections correctly if they have been removed from the motor during service.
(See pre-use check in chapter 3 Installation).
Should swab testing continue to fail, or time is of the essence, install a new (spare) stub shaft (7).
15
5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
* : Relates to the shaft seal.
Step 1
Remove screws, spring washers, clamps (55) and pump casing
(29).
TD 241-012
Step 2
Flushed shaft seal: *
Unscrew tubes (42) using a spanner.
TD 241-020/1
Step 3
Remove covers (22). This is easily done by lifting out the covers,
for example, using a screwdriver.
TD 241-019/1
Step 4
1. Remove impeller screw (36).
2. Remove impeller (37). If necessary, loosen the impeller by
tapping gently on the impeller vanes. The shaft can be fixed
with a screwdriver in the compression ring.
3. Remove the O-ring (38) from the impeller.
TD 241-022/1
Step 5
1. Pull off the O-ring (26) from back plate (25).
2. Unscrew nuts (20) and remove washers (21) and the back plate.
TD 241-023/1
16
5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
* : Relates to the shaft seal.
Step 6
1. Remove the stationary seal ring (11). *
Use the tool
2. Remove the O-ring (12) from stationary seal ring (11).
supplied
left-hand
thread
Step 7
Flushed shaft seal: *
1. Remove screws (41) and seal housing (40).
2. Pull out lip seal (43) from the seal housing.
Step 8
1. Remove the complete shaft seal from stub shaft (7). *
2. Remove spring (13) and rotating seal ring (14) from the drive
ring (10).
TD 241-026/1
TD 241-076/1
17
5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
* : Relates to the shaft seal.
Step 1
1. Remove spring (13). *
2. Lubricate O-ring (15) and fit it in rotating seal ring (14).
NOTE!
Max
Make sure that O-ring (15) has max. clearance from the sealing
surface. 3000-0088
Step 2
1. Refit spring (13) on rotating seal ring (14). *
2. Fit the spring and the rotating seal ring on drive ring (10).
CAUTION TD 241-031/1
Ensure that the driver on the drive ring enters the notch in the
rotating seal ring.
Step 3
Fit the complete shaft seal on stub shaft (7). *
NOTE!
Make sure that the Connex pin on the stub shaft enters the notch
in drive ring (10). TD 241-032/1
Step 4
1. Fit O-ring (12) on stationary seal ring (11) and lubricate.
Use the tool supplied
Left-hand thread *
2. Screw the stationary seal ring into back plate (25).
CAUTION
Only tighten by hand to avoid deforming the stationary seal ring.
(Max. 7Nm)
Step 5
1. Clean the sealing surfaces with contact cleaner before fitting *
back plate (25).
2. Carefully guide the back plate onto adaptor (16).
3. Fit washers (21) and nuts (22).
TD 241-027/1
Step 6
Lubricate O-ring (26) and slide it onto back plate (25).
TD 241-028/1
18
5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
* : Relates to the shaft seal.
Step 7
1. Lubricate O-ring (38) and fit it in impeller (37).
2. Lubricate impeller hub with silicone grease or oil.
3. Screw the impeller onto stub shaft (7).
4. Fit impeller screw (39) and tighten 20 Nm (7.4 lbf-ft).
TD 241-022/2
Step 8
Fit covers (22).
TD 241-019_5
Step 9
Fit pump casing (29), clamps, spring washer and tighten screws
(55).
TD 241-012/2
19
5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Lubricate the rubber seals before fitting them.
* : Relates to the shaft seal.
Step 1
1. Fit O-ring (12) on stationary seal ring (11) and lubricate.
Use the tool supplied
Left-hand thread *
2. Screw the stationary seal ring into back plate (25).
CAUTION
Only tighten by hand to avoid deforming the stationary seal ring.
(Max 7Nm)
Step 2
Flushed shaft seal: *
1. Fit lip seal (43) in seal housing (40).
2. Lubricate O-ring (44) and slide onto the seal housing (40).
3. Fit the seal housing on back plate (25) and tighten screws (41).
TD 241-033/1
Step 3
1. Remove spring (13). *
2. Lubricate O-ring (15) and fit it in rotating seal ring (14).
NOTE!
Max
Make sure that O-ring (15) has max. clearance from the sealing
surface. 3000-0088
Step 4
1. Lubricate O-ring (45) and fit it in drive ring (10). *
2. Fit spring (13) and rotating seal ring (14) on the drive ring.
CAUTION
TD 241-031/1
Ensure that the driver on the drive ring enters the notch in the
rotating seal ring.
Step 5
Fit complete shaft seal on stub shaft (7) so that Connex pin on the *
stub shaft enters the notch in drive ring (10).
TD 241-032/1
Step 6
1. Carefully guide back plate (25) onto adaptor (16).
2. Fit washers (21) and tighten nuts (20).
Note:
Make sure that holes in the seal housing are in a vertical position
TD 241-027/1
20
5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Lubricate the rubber seals before fitting them.
* : Relates to the shaft seal.
Step 7
Lubricate O-ring (26) and slide it onto back plate (25).
TD 241-028/1
Step 8
1. Lubricate O-ring (38) and fit it in impeller (37).
2. Lubricate the impeller hub with silicone grease or oil.
3. Screw impeller (37) onto stub shaft (7).
4. Fit impeller screw (39) and tighten to 20 Nm (7.4 lbf-ft).
TD 241-022/2
Step 9
1. Screw tubes (42) into seal housing (40). *
2. Tighten with a spanner.
TD 241-020/2
Step 10
Fit covers.
TD 241-019_5
Step 11
Fit pump casing (29), clamps, spring washers and tighten screws
(55).
TD 241-012/2
21
5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Lubricate the rubber seals before fitting them.
* : Relates to the shaft seal.
NOTE
Always use Alfa Laval genuine parts and ensure screws do not
protrude from shaft.
TD 247-035/1
Step 2
1. Push stub shaft (7) onto the motor shaft.
2. Check that the clearance between the end of the stub shaft
and the motor flange is 10-20 mm (0.4-0.8”).
TD 247-046/1
10-20 mm (0.4-0.8”)
Step 3
1. Tighten screws (61) lightly and evenly.
2. Ensure that stub shaft (7) can be moved on the motor shaft.
Step 4
Fit back plate (25), washers (20) and nuts (21) and tighten.
TD 241-027/1
Step 5
1. Fit impeller (37) on stub shaft (7).
2. Ensure that the clearance between the impeller and back plate
(25) is correct by using the tool supplied ((1 mm). 0.039”)
TD 241-037/1
Step 6
Tighten screws (61) evenly to 18 Nm (13.3 lbf-ft).
TD 241-036/1
22
6 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
The SolidC pump is designed for standard duty applications, like pumping CIP (Cleaning in Place) solutions, utilities, water
(processing, hydrating, cooling), washing machines, simple transport duty within working range. SolidC is suitable for use in the
food, dairy, beverage, personal care, pharmaceutical, light chemical and water industries.
The SolidC is available in the following sizes SolidC-1, SolidC-2, SolidC-3 and SolidC-4.
Data
Materials
Shaft seal
Motor
Foot-flanged motor according to IEC metric standard 2 poles = 3000/3600 rpm. at 50/60 Hz IP55, insulation class F
23
6 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
The table below specifies the tightening torques for the screws, bolts and nuts in this pump.
Always use the torques below if no other values are stated. This can be a matter of personal safety.
Size Tightening torque
Nm lbf-ft
M8 20 14.8
M10 40 29.5
M12 67 49.0
M14 110 81.0
Motor
Size 90 100 112 132 160 180
1.5kW 2.2kW 3kW 4kW 5.5kW 7.5kW 11kW 15kW 18.5kW 22kW
1 61 63 73 85
2 76 87 108 120 173
3 115 127 180 190 212
4 117 129 179 189 211 267
Weight can vary depending of configuration. Weight is only to be seen as a reference value during handling, transporting and packaging.
24
6 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
The above LKH noise levels are the same for LKHPF, LKHI, LKH UltraPure, LKH Evap, LKHex.
The above SolidC noise levels are the same for SolidC UltraPure.
The noise measurements have been carried out with original motor and shroud, approximately at the Best Efficiency Point (BEP)
with water at ambient temperature and at 50 Hz.
Very often the noise level generated by the flow through the process system (e.g. valves, pipes, tanks etc.) is much higher than
what is generated by the pump itself. Therefore it is important to consider the noise level from the total system and take the
necessary precautions with regard to personal safety if required.
25
7 Parts list and service kits
The drawing shows SolidC pump, sanitary version.
7.1 Drawing
TD241-041_2
US legs are different to the ones shown. For further information, see spare parts catalogue.
TD241-040_2 3001-0058
26
.
27
7 Parts list and service kits
The drawing shows SolidC pump, sanitary version.
2a
FSS
3 18
19 42
40
1
43 44
10 45
13
15
61 41
42
35 14
35a
68 60
39 7
30
10
13 15
30 14
62
63
31 34
16
33 22 17
TD 241-044
20 21
55
29
12
11
25
37 38
26 36
28
7 Parts list and service kits
The drawing shows SolidC pump, sanitary version.
Parts list
Pos. Qty Denomination
20 4 Nut
21 4 Washer
25 1 Back plate
26 ♦ 1 O-ring for casing
29 1 Pump casing
36 1 Impeller screw
37 1 Impeller
38 ♦ 1 O-ring for impeller screw
55 1 Clamp set
29
7 Parts list and service kits
The drawing shows SolidC pump, sanitary version.
2a
FSS
3 18
19 42
40
1
43 44
10 45
13
15
61 41
42
35 14
35a
68 60
39 7
30
10
13 15
30 14
62
63
31 34
16
33 22 17
TD 241-044
20 21
55
29
12
11
25
37 38
26 36
30
7 Parts list and service kits
The drawing shows SolidC pump, sanitary version.
Parts list
Pos. Qty Denomination
1 1 Motor WEG 3000rpm
2 1 Shroud
2a 1 Edge list for shroud
3 4 Screw for shroud
7 1 Shaft
16 1 Adaptor
17 4 Screw for adaptor
18 4 Nut for adaptor
19 4 Washer for adaptor
22 2 Covers
30 2 Bracket
31 4 Legs
33 4 Nut for legs
34 4 Spring washer for legs
35 4 Screw for legs
35a 4 Washer for legs
39 4 Spacer for legs
60 1 Comp. ring
61 4 Screw for comp. ring
62 4 Nut for legs
63 4 Washer for legs
68 4 Washer for legs
31
7 Parts list and service kits
The drawing shows SolidC pump, sanitary version.
2a
FSS
3 18
19 42
40
1
43 44
10 45
13
15
61 41
42
35 14
35a
68 60
39 7
30
10
13 15
30 14
62
63
31 34
16
33 22 17
TD 241-044
20 21
55
29
12
11
25
37 38
26 36
32
7 Parts list and service kits
The drawing shows SolidC pump, sanitary version.
Parts list
Pos. Qty Denomination
Service kits
33
.
34
.
35
How to contact Alfa Laval
Contact details for all countries are
continually updated on our website.
Please visit www.alfalaval.com to access the information directly.