JABSCO Hy-Line Bedienungsanleitung

Hy~Line and Ultima Lobe Pumps

07/03

Installation, Operating, Maintenance and

Spares Manual

Hy~Line

Rotary Lobe Pump

Ultima

Rotary Lobe Pump

Warranty: All products of the company are sold and all services of the company are offered subject to the company’s warranty and terms and conditions of sale, copies of which will be furnished upon request.

The information provided herein is for guidance only, it does not constitute a guarantee of the performance or specification of any individual product or component.

1. INTRODUCTION

1.01 Safety

1.02 Principle of operation

1.03 Operating conditions

1.04 Model numbering system

1.05 Inspection upon receipt

2. INSTALLATION

2.01 Operating limitations

2.02 Location & Positioning

2.03 Drives

2.04 Baseplate

2.05 Guards and safety

2.06 Electrical

2.07 Pipework

2.08 Enlarged rectangular inlet

2.09 Temperature control jackets

2.10 Seals and flushing

2.11 Seal materials

2.12 End Cover relief valve

2.13 End cover barrier

2.14 Overload protection

3. LUBRICATION

4. START UP & ROUTINE CHECKS

4.01 Start up

4.02 Daily Checks

4.03 Weekly Checks

4.04 Monthly Checks

4.05 Six Monthly Checks

4.06 Annual Checks

5. CLEANING AND STERILIZING

5.01 Cleaning in place (CIP) & Manual

cleaning

5.02 Sterilizing in place (SIP)

6. INSPECTION AND REPAIR

6.01 End cover

6.02 Rotors

6.03 Mechanical shaft seals - single primary

6.04 Mechanical shaft seals - single flushed

6.05 Mechanical shaft seals - double

6.06 Seal housings

6.07 Single o-ring seal

6.08 Double o-ring seal

6.09 Multi-Lip seal

6.10 Rotor case

6.11 Rotor clearance - checking &

adjustment

6.12 End cover relief valve

6.13 Thermal jacket –end cover

6.14 Thermal jacket –pump head

6.15 Thermal jacket –rotor case

6.16 Bearing housing - inspection & repair

6.17 Gearbox shafts and gears

6.18 Bearing set-up and pre-load

7. MODEL NUMBER BUILD CODE

8. PARTS LIST AND EXPLODED

DIAGRAMS

8.01 Parts List

8.02 Hy~Line Exploded Diagram

8.03 Ultima Exploded Diagram

8.04 Hy~Line 3 Size Sectional View

8.05 Options & Extras - Sectional Views

DECLARATION OF INCORPORATION

07/03

Hy~Line and Ultima Lobe Pumps

Contents

Jabsco Hy~Line and Ultima

Rotary Lobe Pumps

Installation Operating and

Maintenance Manual

1. INTRODUCTION

Hy~Line and Ultima are positive

displacement rotary lobe pumps designed to

pump delicate, viscous and particle-laden

fluids as well as thin liquids which require an

all stainless steel pump. They share many

common features but the construction of

Ultima differs to provide an exceptionally

high standard of hygiene and cleanability.

This entire manual applies to both pump

ranges, except:

It is essential that anyone who will install,

operate, or be involved with this equipment

shall read the whole of this manual before

installing the pump, as it contains

important safety information. Failure to

follow these instructions could result in

damage to the pump or injury to yourself

or other people.

Adherence to the procedures and

specifications outlined in the following

chapters will assist in providing economical

and reliable operation throughout the life of

the pump.

If service or repair other than that described

in this manual should become necessary,

contact your supplier for assistance.

Any pump returned to the supplier for any

reason must be fully cleaned and

decontaminated and accompanied by

details of what fluids have been pumped,

including full Health and Safety information

(MSDS sheets) if any of those fluids are

hazardous.

All figures in brackets ( ) throughout this

manual refer to the component key numbers

used on the cross-sectional drawings and

the spare parts lists.

1.01 SAFETY

Throughout this manual your attention is

drawn to certain procedures which must be

followed to ensure safe operation and

servicing of this product.

DO NOT ignore safety instructions.

DO NOT remove, by-pass or tamper

with safety devices.

DO NOT use this equipment if the

end cover (122) is removed, guards

are missing or inlet & outlet

pipework is not connected.

DO NOT forget the hazards of

moving parts, high fluid pressure,

extremes of temperature,

hazardous liquids, electricity.

Always isolate and lock-out pump

drive motor before inspecting or

servicing pump.

Page 1

Hy~Line and Ultima Lobe Pumps

07/03

1.02 PRINCIPLE OF OPERATION

Hy~Line and Ultima pumps have 2 rotors

which turn in opposite directions. Fluid

enters the pump from the inlet port and fills

the space between the rotors. This fluid is

carried around the outside of the rotors and

is forced out of the discharge port as the

rotor lobes mesh together see Figure 1.

Each rotor is supported on a shaft and when

the pump is running within its operating

limits, the rotors never touch the inside of

the rotor case, or each other.

1.03 OPERATING CONDITIONS

Hy~Line and Ultima pumps are designed

using modern design techniques and

manufactured from high quality materials.

However, there are certain limitations to the

operating conditions of the pump to ensure

long life and trouble-free running. During

pump selection and specification these

limitations are taken into account and must

not be exceeded.

Every pump is supplied with a Performance

Data Sheet which gives details of these

limitations. These are:-

Maximum Pressure

Maximum Temperature

Maximum Viscosity

Maximum Particle Size

Maximum Speed

Maximum Input Shaft Torque

Maximum Input Shaft Radial Load

These limitations and performance

characteristics vary from one pump size to

another, and from one pump specification to

another within the same pump size.

Take particular care over the following:-

Materials: Ensure that all the fluids to be

pumped, including cleaning and sterilizing

agents, are compatible with the materials

from which the pump is constructed.

See section 2.10 for details of shaft or seal

types and section 2.11 for alternative seal

materials, i.e. seal faces and elastomers.

Page 2

Hy~Line and Ultima Lobe Pumps

07/03

Figure 1

Principle of

Operation

(Showing

Vertical

Mounting)

Hy~Line and Ultima pumps can be used for

duties other than those for which each pump

was originally selected but the new

application must be checked against the

Performance Data Sheet to ensure safe and

reliable operation. Unless you have

experience in the use of this Data Sheet, we

strongly recommend that, if a change of duty

is required, you contact the distributor who

supplied the unit or the manufacturer.

Change of duty means changing any of the

parameters listed above.

1.04 MODEL NUMBERING SYSTEM

A metal plate is fixed to the pump showing

model number and serial number.

The MODEL NUMBER gives important

information about the specification of the

pump, see Section 8 for details. It is

important that the pump specification is

established using Section 8 before any work

is carried out on the pump or parts are

ordered.

The SERIAL NUMBER is unique to each

pump.

Both numbers should be quoted with all

queries or orders for spares.

1.05 INSPECTION UPON RECEIPT

All Hy~Line and Ultima pumps are factory

inspected and tested before packing and

shipping, to ensure safe delivery and

satisfactory service. We would, however,

recommend that you carry out the following

actions upon receipt of your lobe pump:-

a) Remove packing material from

container and check contents against

packing list. Look carefully for small

parts and special tools included.

b) Check the pump for any physical

damage sustained in shipping. If loss

or damage is found, notify your

carrier and supplier immediately.

c) Use lifting equipment as necessary

when unpacking heavy items. See

Performance Data Sheet for weights

of bareshaft pumps. Drives and

baseplates will increase weight

above those shown.

Page 3

Hy~Line and Ultima Lobe Pumps

07/03

2. INSTALLATION

Careful attention to correct installation of

Hy~Line and Ultima lobe pumps, and

recognition of certain limitations to the

operating conditions of the pump, will

ensure long life and trouble-free running.

Failure to follow these instructions

could result in personal injury or

loss of life. Take particular care over

the following:-

2.01 OPERATING LIMITATIONS

PRIMING: Hy~Line and Ultima pumps are

not truly self-priming and should be installed

in a “flooded inlet” pipe arrangement i.e. with

the pump lower than the level of liquid to be

pumped and with the supply pipe falling

continuously to the pump with no loops.

PRESSURE: Do not operate the pump

above the maximum differential pressure

shown on the Performance Data Sheet, not

even for a few seconds, as damage to the

pump components will result, leading to

metal particles in the pumped fluid,

ineffective cleaning and possibly complete

pump seizure.

NEVER run the pump against a closed

valve. Note that the pressure limit

varies with temperature.

SOLIDS: Hy~Line and Ultima lobe pumps

can handle soft solids in suspension but will

be damaged by hard particles. Take care

pumping solids, crystals, etc.

Never allow metal parts to enter pump, e.g.

weld metal, screws, tools, etc. as these will

stop the pump, leading to damaged rotors,

rotorcase and shafts.

CAVITATION: The pumps cannot operate

without sufficient pressure of liquid at the

inlet port to supply the pump. Normally

atmospheric pressure is sufficient but the

actual pressure needed (Nett Inlet Pressure

Required or NIPR), is higher for:-

High Viscosities

High Temperature

High Pump Speeds

Volatile Liquids

Insufficient inlet pressure will cause the

pump to cavitate leading to low

performance, noise and short pump life.

Ensure inlet pipes are short, large bore and

do not collapse under vacuum. Refer to

Performance Data Sheet for Nett Inlet

Pressure Required (NIPR) charts. If in doubt

consult your supplier before operating the

pump.

2.02 LOCATION & POSITIONING

Pump should be located:

• As close as possible to the fluid source

and as low as possible to maximize the

nett inlet pressure available to the pump.

• In a clear area allowing access all around

pump and drive for easy servicing.

• With space above for lifting equipment if

required.

• With port axis vertical if pump is required

to be self draining.

Page 4

Hy~Line and Ultima Lobe Pumps

07/03

All Hy~Line and Ultima pumps are equally

suitable for both directions of rotation.

Hy~Line and Ultima lobe (not LH32 or

LH34) pumps can be rotated to give vertical

or horizontal port orientation with high/low or

left/right input shaft positions. This is

achieved with the bolt-on feet and

re-positionable gear cover. (see Figure 2)

To change any pump from vertical to

horizontal pipework or vice versa, a

conversion kit containing the required feet

and other components is available.

To convert a pump from high shaft to low

shaft, it is necessary only to reverse the feet

and timing gear cover positions as follows:-

Foot Change

Remove key (29) from the drive shaft end.

Remove the 2 bolts (18) from the gear cover

(11) and slide the cover off of the shaft end,

being careful not to damage the inside of the

lip seal on the edges of the keyway in the

shaft. Rotate the cover to the desired

position and re-fit. It is wise to fit new sealing

washers (19) to the heads of the bolts

before re-fitting. Remove the 4 retaining

screws (21) from the feet and re-position the

feet in the desired position. Re-fit the bolts.

For LH72, 74, 76 Pumps - Replacement

feet for vertical seal.

For LH32 and LH34 Pumps:

The LH32 and LH34 size pumps are factory

built with HORIZONTAL PORT orientation

with top shaft position. They cannot be

modified for alternative mountings. To

enable VERTICAL PORT orientation it will

be necessary to mount the pump on an

angle bracket (‘L’-Bracket). A special gear

cover will be required.

Page 5

Hy~Line and Ultima Lobe Pumps

07/03

Horizontal Pipe Orientation,

high drive shaft position

Horizontal Pipe Orientation,

low shaft drive position Vertical pipe orientation

Figure 2

2.03 DRIVES

Hy~Line and Ultima lobe pumps can be

supplied in bareshaft form i.e. without a

drive motor. Drives must be selected and

supplied to suit each individual application.

The prime mover will most likely be an

electric motor but hydraulic or air motors

may also be suitable.

Pay attention to special motor requirements.

e.g. Explosion/flame proof

Hose proof/splash proof

High ambient temperature

Frequent stop/starts

Materials of construction

Provision of a variable motor speed (e.g. by

frequency inverter), is always recommended

to enable flow to be accurately set, to

accommodate changes in fluid viscosity,

temperature or required flow rate, or to run

pump faster for cleaning. Variable speed

motors must selected to accommodate the

full power and torque requirements

throughout the operating speed range.

Transmission to the pump shaft will normally

be by one of the following:

a) Direct Coupling: If synchronous motor

speeds can be matched to the required

pump speed, the drive can be via a

proprietary flexible shaft coupling. A torque

limiting coupling can protect the pump

against overload.

In all cases the coupling manufacturer’s

limits should be adhered to. See

Performance Data Sheet to calculate

torque. Pump and motor shafts should be

accurately aligned in accordance with the

coupling manufacturer’s instructions.

Ultima only: When providing drives for

Ultima pumps it is important to note that the

rotors (57) are retained by tie-rods (26 & 27)

which fit through the hollow shafts (24 & 25).

Careful consideration should be made when

installing drives and couplings so that

access to the tie-rod nuts (87) and tie-rods is

readily available for maintenance purposes.

Use of a spacer type coupling is

recommended.

b) Reduction Gearbox: For pump speeds

lower than synchronous motor speeds, a

proprietary gearbox or geared motor may be

fitted. Variable ratio units are available to

allow pump speed to be adjusted. Coupling

to the pump will be as in (a) above.

2.04 BASEPLATE

The pump and drive will normally be

mounted on a common baseplate or frame

which must be strong and rigid enough to

withstand the drive reaction forces as well

as to support the equipment without

vibration. Ensure base is level - distortion

could affect coupling alignment. Always

check pump to drive alignment after

installation and before starting pump. For

maximum hygiene the pump feet should be

sealed to the base.

Page 6

Hy~Line and Ultima Lobe Pumps

07/03

Maximum shaft radial load stated on

Performance Data Sheet must not be

exceeded.

2.05 GUARDS AND SAFETY

All moving parts must be guarded. Local

safety regulations and codes of practice will

specify the minimum acceptable standard

but as a guide:

• Couplings, belts and pulleys must be

enclosed to prevent fingers, clothing or

tools from touching moving parts.

• Guards must be made from corrosion

resistant materials.

• Guards in hazardous areas must be

made from non -sparking material.

• Guards must be securely fixed.

• Pump must not be operated with guards

removed.

2.06 ELECTRICAL

Electricity can cause injury or death -

follow good practice and local regulations.

In particular: -

Connect electric motor in

accordance with the manufacturer’s

recommendations.

All electrical work must be carried

out by competent personnel to local

safety regulations and codes of

practice.

Take special note of requirements of

the area, e.g. hose-down, high

humidity, explosion proof, etc.

Provide facility to isolate motor

during maintenance, service and

cleaning of pump.

Ensure motor rating plate

corresponds to supply.

Ensure rating of motor and controls

are adequate for duty, especially if

application details have changed

from original specification - see

Performance Curves to calculate

power.

Allow for exceptional circumstances,

e.g. cold start-up.

Provide adequate motor overload

protection.

Page 7

Hy~Line and Ultima Lobe Pumps

07/03

2.07 PIPEWORK

Pipe runs and sizes should be established at

the time the pump is selected. When

installing pump do not deviate from this

design without rechecking pump selection:-

• Keep pipe runs short and pipe diameters

large; pipes may need to be larger

diameter than pump ports especially

when pumping viscous liquids.

• Inlet pipe must be as short as possible

and as large as possible to prevent

cavitation.

• Use large radius bends and full bore

valves. Avoids globe or needle valves on

viscous fluids.

• Fit isolation valves each side of the pump

to simplify maintenance.

• Fit vacuum/pressure gauges each side of

pump to monitor pressure conditions.

Once process is established (and will not

change), these can be removed.

• Avoid filters on the inlet side of pump if

possible. A clogged filter will cause

cavitation. A strainer - maximum hole size

50 microns - will help to protect pump

from damage by particles but must be

kept clear.

• Support pipework - do not allow weight of

pipe (and the fluid within) to be taken on

pump ports.

• Fit expansion joints if necessary to

prevent thermal expansion forces being

transmitted to pump.

• Ensure all pipe joints are adequately

sealed to be a) Air-tight under vacuum b)

Liquid tight under pressure and c) Steam

tight where applicable.

• Take special precautions when pumping

hazardous, hot, toxic or bacteriological

fluids - special joints (e.g. aseptic) and

high specification seals may be required.

• Use hot water/steam jackets or electrical

resistance tape to heat pipes carrying

liquids which thicken when cool. Provide

an interlock to prevent pump from running

unless liquid in pipes is at correct

temperature to avoid over pressure,

cavitation. or excessive drive shaft loads.

2.08 ENLARGED RECTANGULAR INLET

The weight of the hopper (and the product it

contains) must be supported separately and

not allowed to rest entirely on the pump as

this would affect the rotor clearances

leading to pump seizure. The mating flange

of a hopper or screw feeder should be

machined to the identical dimensions of the

rectangular inlet and sealed. This will avoid

ledges where product could ‘hang up’.

Ensure effective flow of viscous material into

the pump.

Page 8

Hy~Line and Ultima Lobe Pumps

07/03

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