NETZSCH Incorporated _ us. Manutacarer of dustrial Byupment_119 Pickering Way Buon, PL 19841-1899 Phone: 610.503.8010 Fax 610:388.09% OPERATIONS AND MAINTENANCE MANUAL ROCK RIVER WATER RECLAMATION DISTRICT PROGRESSING CAVITY SLUDGE PUMPS DIGESTED SLUDGE PUMPS SPECIFICATION SECTION 11160 NETZSCH PUMP MODEL NM090SY01L04K NETZSCH JOB # 0301719800 TABLE OF CONTENT! A. B. Cc. Dimensional Drawings . Performance Curves Pump O&M Manuals Bill of Materials . Spare Parts List '. Chesterton Mechanical Seal Manual Marathon A-C Motor Manual Nord Gear Reducer Manual . Red Valve Pressure Sensor Manual |. Mercoid Pressure Switch Manual [NETZSCH]00861210¢0 #aor [sas iso jf f160 120 40 9 Performance Curve NEMO*-Pump NM 090*1L NETZSCH Data based on water at 65°F a Ops 30 psi 60 psi 20 psi 0 80 100 150 200 (250 00380 400 480500850 NIRPM] oRer Oe eo oO el ei 102 11) ta) pt tt tt tt vg [Bs] PIHP] Net00 [RPM] PIHP] N>100 [RPM] f 90 psi ('=5859 nbs} 60 50 rave ni e = at 40 eS “Ae pO" 30 160 psi {'=4670 infbs 2 i repo 20 10 S = 3 + 0 0 §©50 «100 180 200 250 300 350 400 450 500 550 NIRPM] Startina Toraue TIL) = 6110 inflbs Yaun em + (3095 = 2% s7UeoO ti id Malntenance Instructions N ETZS CH NEMO?-Pump Model Number Sales Order/iob Number Machine Number "in force for the preventior tof accidents and the "environmental protection, « “and its designated use. ‘The Instruction Manual. ‘Contains important inform. tion on how to operate | the machine safely, proper lyand efficiently. Observing “these Instructions help to. In addition to the operating ‘Operation including instructions and to the manda. setting up, troubleshooting ory rules and regulations for « Tip’ the course of work, accident prevention and envi-_ ion ronmental protection in the _ sunt ang place of use of bee noe % ee safe and proper working must’ Must always be available < wherever the machine is in pleted by the end user and - BS Ene ee authorized personnel with, ‘Netzich Incorporated ity P: 119 Plkering Way * Exton, PA 19341 @ NEMO: Registerea —- UAlity Pays NETZSCH 610.363.8010 * Fax: 610.363.0971 trademark of NETZSCH For isef ——s ‘emai: [email protected] MOHNOPUMPEN GMBH. wwwnetzschusa.com[_NEMO-NMstacewitn packing #2001 N ETZSCH TABLE OF CONTENTS a 1.) Safety Precautions 1 2.) Description 2 3.) Packing, Transportation, Storage 3 4.) Installation Instructions 4 5.) Start-Up 5 6.) | Temporary Shutdown 6 7.) Maintenance 7 8.) Trouble-Shooting and Solutions 8 9.) Disassembly and Assembly of the Pump Housing 9 10.) Disassembly and Assembly of the Rotating Parts 10 11.) Disassembly and Assembly of the Bearings 1 12.) Disassembly and Assembly of the Shaft Sealing 12 13.) Disassembly and Assembly of Special Units 13 14.) Recommended Spare Parts 14 15.) Parts List and Sectional Drawing 15NETZSCH, , SAFETY PRECAUTIONS PAGE 1 Safety Precautions ‘These operating instructions contain essential information which should be observed during installation, operation and maintenance. These operating instructions should be read and understood by the engineer, as well as other responsible operators before assembly and operation. Operating instructions should always be readily available wherever the machine is being used, >> b> > Continued on Page 1.0R The general safety rules detailed under “Safety Precautions”, plus the safety precautions set by the end user, must be followed. 1.1. Symbols Relating to Safety Precautions in the Operating Instructions Personal injury, damage to machines or con- tamination of the environment can result if the safety precautions contained in this document are not strictly enforced. Following are signs ‘commonly used to signify areas of danger: Safety Sign Danger to General Public Safety Sign Electrical Hazard Danger from Possible Injury by Machinery Danger from Suspended Loads Damage to MachineryPAGE 1.0R 1 SAFETY PRECAUTIONS Waring or indication plates attached to the PUMP Which show the correct direction of rota tion (or fluid connections) must aways be kept in readable condition. 1.2. Qualifications and Training of Personnel ‘All personnel responsible for service, mainte. nance, inspection, installation and operation must have the appropriate training. Responsibility and supervision of personne! must be strictly enforced by the end user. If training of personnel is required, it can be provided by the manufacturer/representative. Furthermore, it is the responsibilty of the end user to ensure that personnel fully understands the operating instructions. 1.3 Nor-Observance of Safety Precautions No-observance of the safety rules can result in personal injury, damage to machines or con- tamination of the environment. Nor-obser- vance can void product warranty. Non-observance can also result in the following © Premature failure of components or machine/equipment malfunction. © Danger to personnel from electrical, mechanical or chemical hazards. @ Danger to the environment from leakage of dangerous materials. Continued on Page 1.1 1.4. Safe Operation The safety precautions outlined in these oper- ating instructions, the existing national regula- tions on accident prevention and the end users ‘own operating and safety regulations must be observed. 1.5. Safety Precautions Hot or cold machine components must be insulated or shielded, % Guards covering moving parts (i. shafts, couplings) must not be removed while machines are in operation. Leakage of dangerous materials (i.e. expio- sives, toxins or hot materials) from the shaft sealing area should be properly contained. # Inorder to prevent electrical hazards, appli cable local and/or federal regulations must be adhered to,NETZSCH , SAFETY PRECAUTIONS PAGE 1.1 1.6 Safety Precautions for Maintenance, inspection and Installation Work ‘The end user must ensure that all maintenance, inspection and installation work is performed by authorized and qualified personnel who understand the operating instructions and are properly trained. Work on a pump/machine should only be performed when it is disconnected from its Power source, pressure has been relieved, and the complete unit. has returned to room temperature. it is imperative that these procedures are adhered to before attempting work on the machine. Pumps or units which transfer dangerous substances must be decontaminated, Immediately following maintenance work, all safety and protection equipment must be re- installed and safety trips must be tested. Refer to Section 5.0, “Startup,” before restart ing machine/pump. 1.7. Unauthorized Use of Spare Parts and/or Modifications to the Pump Modifications to the machines and/or its com- ponents are permitted only with the manufac- turers consent. Original spare parts and acces- sories authorized by the manufacturer ensure safety. The use of other components revokes any warranty and liability for consequences which may result, Continued on Page 1.1R 1.8 _ Improper Application Machinery is only guaranteed safe for the use specified. This machinery was manufactured in accordance to the specifications and the conditions specified by the end user The machine should not be operated in any way that exceeds design capacities. 1.9 Specific Points for the Use of NEMO” Pumps NEMO* Pumps should only be used for the application for which they were sold, If you wish to change the pumping medium, you should check with either the supplier or manufacturer to ensure that the pump will be suitable for the new medium. This is especially important with aggressive, poisonous or ‘otherwise dangerous media. Criteria for the selection of a pump includes: 1. Compatibility between the medium to be pumped and the materials of all wetted Pump parts. 2. Compatibility between elastomeric components and mechanical seal faces. 3. The pressure and temperature rating of the pump. NEMO® Pumps are of positive displacement progressing cavity design, and have the potential to generate very high pressure.PAGE 1.1R 1 SAFETY PRECAUTIONS A blockage or closure of a valve in the discharge line can cause a pressure rise higher than the installation can withstand. A substantial pressure increase can result in the bursting of pipes and/or damage to other components of pump or drive systems. Extreme caution must be used, especially when dangerous media is present. Appropriate safety equipment must be installed (ie: an emergency stop button, a pressure relief valve or rupture disc}. During maintenance and repair work on the pump, please note the following: 2 No one other than those involved with maintenance and repair should have access to power supply. When dismantiing the pump, follow the instructions for handling the medium {e.g.: protective clothing, no smoking, ete.) Before putting the pump back into operation, ensure that all guards and other safety devices (e.g.’ drive belt and coupling protection} are properly reinstalled. ‘Always keep safety in mind during operation, maintenance and install- ation of equipment. Please adhere to.applicable federal and local rules and regulations. Continued on Page 1.2N ETZ 5 CH 1 SAFETY PRECAUTIONS sn 1.2 1.10 Notes on Inspection and Repair itis the responsibility and obligation of all commercial businesses to enforce safety in the workplace, regulations governing dangerous materials, accident prevention and environ mental protection at all times. People along with the environment must be protected from adverse effects caused by contact with dangerous materials. The procedures for proper handling, containment and/or disposal of all hazarcous materials, including wastewater, must be strictly enforced. Important A Material Safety Data Sheet must accompany any machine/part and a Safety Conformity Certificate must be completed prior to inspection or repair. Please make a duplicate copy and leave the original in the Operation and Maintenance manual. ‘Where special safety precautions are necessary, in addition to careful emptying and clean- ing of the machinery, the necessary information must be given. Inspection or repair of machinery containing radioactive medium will only be performed by authorized personnel under protection and supervision of the owner. The Safety Conformity Certificate is part of the-inspection/repair service. We reserve the right to refuse acceptance of this order/service for other reasons. Continued on Page 1.3NETZSCH 1 SAFETY PRECAUTIONS PAGE 1.3 Safety Conformity Certificate This completed Safety Conformity Certificate and a Material Safety Data Sheet must accompany the machine and its accessories when retumed to the manufacturer for repair/inspection services. Pump Model Number, | Job Number Date of Manufacture Equipment Return Authorization # Machine Number Was carefully emptied and cleaned, both inside and out, Dyes in preparation for shipment. ONo Precautions with regard to health and Oves the environment are to be observed CINo This machine came into contact with media hazardous Cives to health and the environment. CINo The following additional precautions are necessary with regard to the handling of media and the disposal of waste: We confirm the above information is dccuraté and’ complete, and shipment will be in accordance with legal requirements: Company Telephone No." Fax No. Address Name Date: Position: Company Stamp/SignatureNETZSCH —————T 2 DESCRIPTION AND GENERAL DATA! PAGE 2.0 2 Description ‘The Nemo® Pump is a positive displacement progressing cavity-ype pump. The main components of the pump {which was invented by Professor Rene’ Moineau) are: a rotating part, called the rotor; and a station- ary par, called the stator. The rotor has a single helix shape and is normally made of a metallic material. The stator is formed as a doublehelix with twice the pitch Of the rotor and is normally an elastomer. The interference [compression] fit between the rotor and stator creates a series of sealed chambers called cavities. When the rotor turns inside the stator the medium moves continu- ously from the inlet to the outlet of the cavities. The NEMO? Pump principle utilizes many post tive characteristics of other pump types: + ke centrifugal pumps, NEMO? Pumps have no suction or pressure valves, but do have a stable flow rate in proportion to the number of revolutions Uke piston pumps, NEMO* Pumps have a suction lift up to 28", Vacuum capacity is 24-25. Like membrane and peristaltic pumps, NEMO* Pumps can transport all types of media including inhomogeneous, gaseous and abrasive media; as well as those that are not of a liquid consistency, ‘or contain solids and/or fibrous material Like gear pumps and screw pumps, NEMO? Pumps are capable of handling highviscosity mecia, Continued on Page 2.08 Like piston, membrane, gear or screw pumps, NEMO® Pumps can be used for metering applications. Length and cross-sections of the rotor and stator during a rotation.PAGE 2.0R 2 DESCRIPTION AND GENERAL DATA 2.2 General Data Noise Emissions: The maximum noise emission level permitted at a workplace is 85 dB (A). Noise levels are measured in accordance with OSHA CFR 1910.95 to assure that the pump does not exceed 85 dB (A) Noises generated by the drive and pipes are not included in the above emission value. In order to maintain a noise emission level of < 85 dB (A), the pump must be securely mounted and not allowed to cavitate.NETZSCH ——_ 3 > PACKAGING, TRANSPORTATION, PAGE STORAGE 3.0 3 3.1 Packaging and Transportation NEMO® Pumps are shipped on skid-mounted woodframed cardboard enclosures, unless the customer specifies otherwise. The packages are labeled with any special handling instructions. Upon receipt, inspect the pump for any transportation damage. Claims for damages should be reported to the freight carrier immediately. LN Packaging, Transportation, Storage Unerated horizontal pumps should be lifted using the bolt holes of the frame or the lifting lugs attached to the baseplate. Vertical pumps should be lifted by using the bolt-down holes, or lifting lugs attached to the mounting plate. Use caution when lifting top-heavy pumps. The center of gravity may be above the points where the lifting gear is attached. If thisis the case, secure additionally to prevent tipping over! Vertical pumps should be stored horizontally only, unless they are secured, vertically. This will prevent hazards of tipping! AX the gear box only, Avoid suspending the complete pump unit by the eye bolts of the motor ‘or gear box. These eye bolts should be used for lifting the motor and/or ‘As when operating any type of equipment, exercise caution and adhere to all applicable instructions, rules and regulations. Due to the variety of possible pump designs and applications, only gener- al instructions can be given here. These should be adequate for experi enced assembly or transportation personnel. When in doubt, contact the supplier for more detailed information. Continued on Page 3.0RPAGE 3.0R 3 PACKAGING, TRANSPORTATION, STORAGE When moving the pump or unit on wheels, strictly adhere to the following: © Lock out the motor drive to protect against unintended startup. Move the pump unit carefully and slowly, especially where the ground is uneven. Hazards of tipping! The pump should be stored in a stable position with wheels or rollers locked or otherwise secured. Be careful not to allow flexible piping to bend or become kinked. Obstruction of flow will cause excessive discharge pressure. * Where necessary, secure the pump unit with additional support blocks. 3.2 Storage Pumps are packaged for transportation and short-term storage. In cases of profonged storage, the pumps should be protected as follows until installation: Stator: When stored for a long period, the elastomer along the contact line between the rotor and stator may become termporarly distorted [coripression-set). This will increase the required starting torque. For this reason, the stator should be removed and stored in a cool, dry place in an airtight package and protected from light. ‘Shaft Sealing by packing gland: Remove the packing gland and protect the exposed shaft surface with protective grease or oil. + Pump parts in stainless steel: No protection necessary, + Other norprotected pump parts: Protect with grease or oil Drives: Observe the instructions of the drive supplierN ETZSCH 3 PACKAGING, TRANSPORTATION, PAGE STORAGE 3.1 TF Store Room The environment in which rubber products are being kept must be cool, dty, free of dust and well ventilated, and must not be stored in the open. Rubber products should be kept in surroundings not having less than minus 10° C (14° F) and not more than plus 15° C (59° F]. Store rooms should not be damp, and it must be ensured that there will be no condensation. Recommended relative humidity is < 65%. Rubber products must be protected against light, particularly direct sunlight or artificial light having a high UV portion. Rubber products should be kept in a sealed package. ‘As ozone is very aggressive and harmful there should be no store room used which ‘houses equipment likely to produce ozone, i.e. electric motors or other equipment Which might bring about sparks or other electrical discharges. There must be no solvents, oil, grease, lubricants or any chemicals kept in the store room. # Rotor Support with wooden blocks and protect against damage from mechanical impact. For tool steel rotors (material number 1.2436): coat the surfaces with protective grease to avoid rusting + Shaft Sealing by packing gland Remove the gland and coat exposed shaft surface with grease or oil © Pump parts in stainless ste! No grease coating necessary. Other, non-coated pump parts Protect with grease or oll + Drives Observe instructions of the drive supplierPAGE 4.0 4 INSTALLATION INSTRUCTIONS 4 Installation If the NEMO® Pump was stored and the rotor grease protected: Remove the grease before installing the stator. Clean the rotor thoroughly in order to avoid contamination of the stator and the pumping medium, Verify all hardware has been properly installed and fastened. 4.1 Direction of Rotation The direction of rotation of the pump is given on the name plate. 4.2 Pressure Maximum permissible pressure inside the pump housing (A) is 6 bar. The maximum permissible pressure inside the end flange (B) is 12 bar. Type key Example: Series Pump Size Drive End Execution” ___ Number of stages Geometry __ max. permissible pressure differential (counter clockwise rotation) _| Joint Type 4.3 Shaft Sealing © Where applicable, ensure that adequate supply lines for the buffer, flushing or quenching fuid for the shaft seals are connected before the pump is put into operation. For more details see Section 7.4! Continued on Page 4.0RNETZ5 CH 4 INSTALLATION INSTRUCTIONS eee 4.0R 4.4 Piping System ‘Arrange suction and discharge pipes so that when the pump is not running, the medium is still present, Sufficient medium should remain inside in order to lubricate the pump during restart # Clean the pipe work and rinse thoroughly before installing the pump. ‘+ See chart below for recommended disassembly (ABL] dimensions. Disassembly length ABL in mm: Pump ‘Number of Stages size 16 2 3 4 6 8 19 12 - O15 160 |_160 | 230 | 310 | 460 | o10 | 770 | 920 o2r | 230 | 230 | 340 450_| 670 ga0_ | 100 | 1310 031, 310 | 310 [ 450 | seo | ao | 1160 | 1490 | 1730 038 430_| 430 | 630 | 830 | 1230 | 1630 | 2030 | 2430 045 soo | soo | 730 | 960 | 1430 | 1890 | 2350 | 2820 053 600 | 600 | aso | 1170 | 1730 | 2290 | 2800 | 3420 063 e90_| 690 | 1010 | 1330 | 1980 | 2620 | 3270 | 3910 076 oo | 800 | 1170 | 1540 | 2280 | 3030 | 3770 | 4520 o90 | 950 | 950 | 1390 | 1840 | 2720 | 3610 | 4500 1o5__| 1120 | 1180 | 1740 | 2300 | 3410 | 4520 125 | 1400 | 1400 | 2060 | 2720 | 4040 t4e__|_1680 | 1680 | 2470 | 3260 130 | 1910 | 1910 “This dimension applies to IL geomet, 2 bwoughl?2 refer to 5 geometyPAGE 4.1 4 INSTALLATION INSTRUCTIONS The twisting loads (Fx, Fy, Fz) and bending loads (Mx, My, Me) permitted for the suction/discharge flange comply with the requirements of API 676. They are shown in the table below. Pump Standard My, My, My type nominal diameter NM ON Ios ins oe NPT joints 008 As 38 must not be assembled on with loads which may ois result in over tightening ei FNPT 95 oF loosening these joints 31 2 152 3080 38 25° 191 3828 45 53 x 229 4576 63 + 305 6116 7% o 382 7612 90 105 6 458 9152 125 s on 12,188 148 10" 764 15,224 180 10" 764 15,224N ETZS CH 5° STARTUP PAGE 5.0 > > & 5 Startup . NEMO® Progressing Cavity Pumps must be operated with the following precautions: Never run the pump dry! Even a few rotations in dry condition will damage the stator. If the rotor was protected with grease for long-term storage: Thoroughly clean the rotor to prevent damage caused by interaction of the grease, stator material and medium, © Before initial startup, regardless of rotation, make sure the pump housing and suction piping are filled with medium. If medium is high in viscosity, it may be necessary to prime the pump with a compatible liquid. Priming of the pump is necessary to lubricate the stator. NEMO® Pumps are positive displacement progressing cavity pumps and have the potential to generate very high pressure capable of bursting vessels or pipes. Excessive pressure can overload the drive train {shaft, connecting rod, joints, rotor) or exceed pressure limitations of the housings and their connections, resulting in damage or breakage. Refer to Section 4.4 of this manual for housing pressure limitations. Never run the pump with an inlet or outlet vaive closed. @ Open valves and vents before starting the pump! Tum pump motor on and off briefly to check direction of rotation.PAGE 6.0 6 TEMPORARY SHUTDOWN An 6 Temporary Shutdown % Following the temporary shutdown, the pump should be emptied and rinsed when - the pump is installed in a location inside or outside where the medium hhas the potential to freeze. ~ the medium has a tendency to solidify or harden. ~ the medium tends to build up or become tacky on the shaft sealing area. + Stator: When stored for an extended period, the elastomer along the contact line between the rotor and stator may become temporatily distorted [compression-set This will increase the required starting torque. For this reason, the stator should be removed and stored in a cool, dry place in an airtight package and protected from light. © Rotor: Support with wooden blocks and cover to protect from mechanical damage, after the stator has been removed. Rotors made with Tool Stee! (Material number 1.2436) Should be protected against corrosion with protective grease. Prior to installation, thoroughly clean rotor to prevent damage caused by interaction of the grease, stator material and medium. ‘Stand-by Pump: A stand-by pump is sometimes installed to eliminate downtime. Stanc-by pumps should be operated occasionally to keep properly conditioned for use.N ETZ5 CH 7 MAINTENANCE a 7.0 7 Maintenance 7.1 Pumps in General ‘The pumps should be regularly rinsed or cleaned if deposits of medium are likely to build up. fs If the pump needs to be disassembled, ensure that the pump and motor are switched off and cannot be turned on accidentally (eg. by removing the fuse). 7.2 Lubrication The NEMO® Pump does not require frequent lubrication. ‘ Maintenance and lubrication of the drive should be carried out according to the drive manufacturers instructions.PAGE 7.2 7 MAINTENANCE 7.3 Lubricating the Gear Joints with SM Joint Seals Cis advisable to change the oil and check the seals of the pin joints: + when replacing worn joint parts = when disassembling the pump for any reason Joint Quantity of oil per joint basic size series NM om loz NM 038 7 0.57 NM 045 22 0.75 NM 053 32 1.08 NM 063 80 271 NM 076 150 5.07 NM 090 260 8.79 NM 105 360 12.17 Continued on Page 7.28NETZSCH 7 MAINTENANCE PAGE 7.2R Lubricating Oil: Industrial Designation . Product Application DIN'S1502 Permitted Product re “SHELL” Omala 460 (or equivalent) General Industry with SMpin joint seal (8235) of EPDM prescribed: CLP PG. KLUBERSYNTH 320 GH 6-320N ETZS CH 8 TROUBLE-SHOOTING PAGE 8.0 8 Trouble-Shooting 8.1 TroubleShooting Guide The following chart lists possible problems and corresponding solutions: 8.2 Determining the Kind of Problem and the Possible Cause ~The column describing a possible problem shows one or more boxes marked with an "x." + On the corresponding lines, you will find the possible Feasons/causes and some hints how to handle the problem. ‘Thus, the actual cause of the problem can be narrowed down and eventually detected. ‘© The table helps to identify the problem and offers a possible solution. For more complicated problems, consult the manufacturer. Continued on Page 8.0RPossible Problem TROUBLE-SHOOTING GUIDE A good service life can be expected if | § 2 sls the pump is used in accordance with 3 3 3 € : s your specified application and i = al § q gla2| S| _ | Maintained in accordance with this man 5 BM EIEE g g 'g| 8| ual. If operating problems arise, use this % 8] 8) 8) 81 2/2] 8] §| §| g| chart as a guide in locating the problem. 5 £ SSS] 5] E/E S| Sl 8/8 2 a] 3/88 |alelelslsialé POSSIBLE CAUSE z x x Pump or stator is new, to much static friction 1 x] [xp x Power supply incorrect, drive not properly wired. 2 x X{x]x] [Discharge pressure too high. 3 x x] x Foreign matter or debris in pump. a x x|x[x]x | [Temperature of pumped liquid too high stator swells. _| 5 x x[x]x Stator swells due to chemical attack, unsuitable elastomer 6 x x] x] x Liguid contains too many solids, causing blockages. 7 x [x [9] | Liquid settes and hardens at pump shutdown, & FIRES Air in suction piping, 9 x [x[x|x Suction pipe leaks. 10. x px Shaft sealing leaks. 1 x 1x Pump speed too low. 12 x Px Undersized rotor; operating temperature not reached. | 13 x] xp 3] | Discharge too high or suction head too low (cavitation). | 14 __bepd Daca x icc Pump running dry. ar x] x}x] [x Stator worn out. 16 x{x[x] [x [x] _| Stator material britde 7 x| xx] [x x Rotor worn out 18 x Joints worn 9 x Pump and drive out of alignment. 20 x Elastomer in coupling worn out. 21 x X | Pump bearings wom. 22 x Pump speed too high. 23 x Viscosity too high. 24 x Specific gravity too high. 25 x X | Stuffing box not property tightened 26 1X | incorrect packing 2 X [Wrong direction of rotation. 28 x X | Stationary or rotating face of mechanical seal wom. | 29 X | O-Rings in mechanical seal worn or damaged 30NETZSCH 3 romacsiooine CORRECTIVE ACTION Fill pump and tum by hand. If necessary, use glycerine to lubricate stator. ‘Check motor nameplate data, Test voltage, phase and frequency. Measure actual discharge pressure and compare to your specification. Remove debris and correct any damage. If liquid temperature cannot be reduced, use an undersized rotor, Check specfied application, if necessary, change stator material Increase liquid-to-solids ratio. @]SJoJayeyoxy— ‘Clean pump and rinse out after each use. Increase NPSHA; eliminate leaks (see No. 10) ‘Check seals: tighten piping connections. u Packing: tighten stuffing box or replace packing. Mech. seal:_replace rings or seals; remove deposits 12 If drive is variable speed, increase speed at pump. 13 Heat pump [stator] to operating temperature 14 Reduce suction losses; lower quid temperature; install pump at lower elevation. 15 Fill oump: provide dry run protection: relocate suction piping. 16 Replace stator 7 Replace stator check specified application: change stator material of construction if necessary. 18 Replace rotor; determine cause; change rotor material of construction if necessary. 19 Replace necessary parts: seal and refit carefully. 20 Realign pump and drive 2t Replace coupling elastomer, realign. 22 Replace bearings, lubricate and seal. For high temperature, check bearing tolerances and lubrication. 23 If drive is variable, set at lower speed, 24 Measure viscosity and compare to specified viscosity. 25 Measure specific gravity and compare to specified specific gravity. 26 Service stuffing box: replace wom shafts. 27 Change packing material 28 Reverse polarity of drive motor 29 Rework or replace seal faces 30 Replace orings: check specified application. Change o-ring material of construction if necessary.PAGE 9 DISASSEMBLY AND ASSEMBLY 9.0 OF THE PUMP HOUSING 9 Removal and Assembly of End Flange, Stator and Pump Housing AX The pump with attached pipework should be empty and must have cooled off + Disconnect the pipework on the suction side and pressure side of the pump. Remove securing hardware, from support feet to baseplate + Remove the hex nuts (3020) with spring washers (3015) # Remove the end flange [2035] from the stator (3005). Remove the stator (3005) + Remove the pump housing (2010) from drive stool (0085] or bearing housing {0005}, Reassemble in reverse order, Installing the stator {3005} will be easier when using glycerine as a lubricant. > Ensure during refiting-that-gasket {81 10} 's in perfect condition and will seat property. Torque values for hex nuts (2030) se | M6 | ma | mio | wiz | m6 | mzo | M24 | M30 Required torque | 70. | 132 ] 264 | 396 | 660 | 704 | 880 | 1056 infos.NETZSCH 10 DISASSEMBLY AND ASSEMBLY PAGE OF THE ROTATING PARTS 10.0 10 Disassembly and Assembly of the Rotating Parts with Gear Joints with SM-Seal Cover 10.1 Removal of Rotor and Coupling Rod # Place the dismantled unit consisting of bearing housing {0005} or drive stool (0085) with drive (A) and connecting shaft (1050), coupling rod (1998) and rotor (1999] on the workbench with a wooden, block supporting the rotor (1999) 9005 ios 1999 1988 oo8s 1050 Note when draining the oi! The oil inside the gear joints may be under pressure. Wear Goggies! — Remove drain plugs {5051} from the complete gear Joints (5015) and drain the oll into a receptacle. Lubricant: See Page 7.2, Section 7.3 - Lubrication. é Unscrew cylindrical head screws (5035) from the ‘two clamp ring halves {5010}. t j 1999, sas 0 Pull apart bearing housing (0005) with drive shaft {1005} or drive stool (0085) with drive {A] and t ae connecting shaft (1050) from the coupling rod (1998) ‘ S and rotor (1999) Continued on Page 10.0RPAGE 10 DISASSEMBLY AND ASSEMBLY 10.0R OF THE ROTATING PARTS 10.2 Disassembling the Gear Joints Secure the coupling rod (1998) with the two open gear joints (5015) vertically in the vice and dismantle the two complete gear joints as follows: # Remove the set screw (5048), unscrew the hex nut (5043) and remove the washer {5050}. Pull the complete joint unit consisting of joint shell {5005} with gear joint (5015), clamp ring (5085) and ‘SMseal cover (5086) off the coupling rod (1998). Taking care that done of the parts drop out! % Remove the complete gear joint (5015] from the joint shell (5005) and dismantie, See also sectional drawing 6. # Remove the Oring (5105) Unscrewing the cylindrical head screws (5095) remove the joint shell (5005) with O-ring (5106) from clamp ring (5085) and Siseal cover (5086). # Take the SMseal (8021) away from the joint shell (5005). Reclamp the coupling rod (1998) the other way up and dismantle the second gear joint (5015) in the same manner. # Iadapters are fitted: See page 10.5, Section 10.6 - Removal and Fitting of the Adapters, a 5085 501s ta 8N ETZS5 CH 10 DISASSEMBLY AND ASSEMBLY PAGE OF THE ROTATING PARTS 10.1 10.3 Assembly of the Gear Joints with Double Sealing (SM-Seal Cover) In order to avoid mistakes which could lead to increased wear or damage to the pump, please carry out the installation according to the following directions: Secure the coupiing rod (1998) vertically in the vice close to the top. Slip the O-ring (5105) over the splined end of the coupling rod (1998) and place it on the sealing 188 shoulder iy Place the SMseal cover (5086) with the O-ing (5106) = into the clamp ring (5085) 4 Secure the joint shell 5005} to the clamp ring (5086) : 08 with the cylindrical head screws [5095]. 1S g 985 Slip the joint shett (5005) with the SMseal cover (5086) | $9T—Lk___song and the clamp ring (5085) over the end of the coupling rod {1998} and push by hand down to the shoulder. 5086 1908 # In general, its quite useful to fil the inner part of the seal cover (5086) with liquid It can be done without liquid, though there is no overpressure in the pump housing Filing with liquid, however, is of the utmost importance should there be overpressure in the pump housing soes through the clockwise rotation of the pump, feeding pressure in anti-clockwise rotation or C.I.P cleaning ra procedure. Continued on Page 10.1PAGE 10 DISASSEMBLY AND ASSEMBLY 10.1R OF THE ROTATING PARTS If both the seal cover (5086) and the SM-seal (8021) = ay are of cil resisting material eg NBR (Perbunan|, FPM ~ | Say [Miton} or PUR (polyurethane], a standard lubricating il may be used to fill the gear joints. NBR Where the seal cover (5086), and in contrast to the FPM it ‘SMseal (8021), isin non-oil resisting material eg PER EPOM rubber glycerine should be applied for the filing, EPDM glycerine © Fill the seal cover (5086) with liquid to about the Upper edge of the inner metal part A which sits on the coupling rod (1998). © Apply some grease to the SM-seal {8021} in the center and around the outer lips (lighter installations) and push by hand over the end of the coupling rod 1S—a 11999) up to the shoulder into the joint shell (5005) In doing so, a small amount of liquid {as described 7 above) is abundant from the seal cover (5086] and 5085 is being forced up through the area around the joint 1998 shell (5005) Where the abundant liquid is glycerine, this should be removed! With the SMseal (8021) fitted snug into the joint g SS shell (5005), the lower cover (5015.4) of the gear joint (5015) may now be pushed over the coupling rod [1998} down onto the SM-seal (8021) into the joint shell{5005). Continued on Page 10.2N ETZ5CH 10 DISASSEMBLY AND ASSEMBLY PAGE OF THE ROTATING PARTS 10.2 # Please compare sectional drawing G...! Place the gear (5015.3) in the correct orientation on the gear rim (5015.1), where the cover (5015.2) is bonded in. Mark a tooth on the gear (5015.3) and also mark the tooth opposite on the gear rim (5015) For correct position proceed as follows: # The bondedtin cover (5015.2) should lie at the bottom, whereas the plain part (F] of the gearing is on the top (see illustration above). The gear rim (5015.1) will ft together with the gear (5015.3) in this position only (odd number of teeth). Ifa gear does not fit freely into a gear rim, rotate the gear 180°. The gears should slide together, excessive force should not be used! ‘@ Take the gear (5015.3) off the gear rim (5015.1), and turn upside down. Then slide the gear with the plain part (F] of the gearing ahead onto the top’ of ine’ coupling rod AN (1998) and push down to the shoulder. If the fit of the gear (5015.3) is tight, gently tap with a plastic hammer. Putin the keys (5030). Place the gear rim (5015.1) with the bondediin cover, (5015.2) into the joint shell (S005), taking care that the marks on the gear rim (5015.1) match with those of the gear (5015.3). See illustration above. Rotate the joint shell (5005] so the lubricating bores {5} are fitting together. = |Continued on Page 10.2RN ETZSCH 10 DISASSEMBLY AND ASSEMBLY PAGE OF THE ROTATING PARTS 10.2R Put the washer (5050) on Remove the set screw (5048) Screw the hex nut (5043) on to the coupling rod (198) Adjust the hex nut (5043) with the torque key to the prescribed torque. Torque value: See the table below. Secure the hex nut (5043) with the set screw (5048). Torque settings for hex nut {5043} Joint Joint Required ‘outer diameter Basic torque in Dinmm Size inches/ibs 84 NM...045 180 4 NM...053 270 110 NM...063 450 $24 mm + NM..076 200 7 144 NM...090 900 158 NM...105 2700 Continued Page 10.3anaerobic (eg. Loctite 245). Tighten cylindrical head screws (5035) evenly in pairs over cross = @ Remove the coupling rodyotor unit from the vice, | = NETZSCH 10 DISASSEMBLY AND ASSEMBLY PAGE OF THE ROTATING PARTS 10.3 10.4 Fitting of the Rotor and Coupling Rod Install the Oring (8025). ° 1999 Orient the rotor (1999) over the joint shell (5005) so the key ways of the rotor (1999) engage into the keys (5030) 5025 oO '@ Slot the rotor (1999) into the joint shell (5005). If the [Ik 5030 fit is tight, gently tap the end of the rotor (1999) with a plastic hammer. g a Mount the two clamp ring halves (5010) and secure | 1050 with cylindrical head screws (5035) which should be . _ rotate the unit and reclamp the coupling rod (1998), at its free end now at the top. Assemble the second gear joint (5015) as detailed in } section 10.3 q Connect the bearing unit with the drive shaft (1005) or the lantern unit with the connecting shaft (1050) wy to the second assembled gear joint (5015). With 2/3 geometry pumps ensure that the pump housing should have been slipped over the coupling rod/rotor unit beforé assembling to the gear joint. 100s} ,0005 008s See also Section 9. | With larger pumps (NM063 and larger) the bearing | orintumurkstodd be supences yecernona | tel a lowered until the key ways of the drive shaft (1005) = b ‘or connecting shaft {1050} engage the keys (5030). When the assembly is completed, lay the assembled 1090 L rotating unit on a work bench,N ETZSCH 10 DISASSEMBLY AND ASSEMBLY PAGE —_—_—S OF THE ROTATING PARTS 10.4 10.5 Filling the Gear Joints with Oil Lubricant: See Page 7.2, Section 7.3 - Lubrication After assembly the complete gear joint should be filed with oil as follows: * Aspecial filing device is available under Indent No. 155 583 including an oil can, two MB connecting fittings and two hoses. If there is no such filing device at hand, the following describes and illustrates a do-ityourself construction., ® By heating the oil can to about 40 - 50°C, the oil will become thinner and the pumping is easier This could be done in a vessel holding hot water. © Screw a fitting into the M8 thread of the oil fil ports (2) on the joint shell (5005). An M8 stud with a 4mm drilled bore could be used for this purpose. Now rotate the joint shell (5005) so one of the two oil fill ports (2) is pointing downwards and screw in the hose fitting which should be connected to an oil, ‘can (or pump bottle} Pump the oil can slowly. At the same time move the Coupling rod (1998) and compress the SM-seal a few times to disiodgé any trapped ai "When bubble free oll from the overflow discharges, the joint is filled # Remove the discharge hose and screw a drain plug (5051) in the upper oil port (2), thus closing off the joint shell (5005). For Sealing and Securing: See Page 10.4R. Now turn the oll fil port upwards, remove the oil can [or pump bottle} and pour in some more lubricating oil until the joint shell (5005} is completely full Then screw in the second drain plug (5051) as described above. Continued on Page 10.48PAGE 10 DISASSEMBLY AND ASSEMBLY 10.4R OF THE ROTATING PARTS Remark: The drain plugs (5051) applied are made of A$ and they are especially threac-coated. Coated drain plugs do not need any additional sealant on the first assembly. To ensure safety, use the coated drain plugs only once! For possible re-application already coated drain plugs should be recoated again, preferably by using PTFE-mpregnated tape or standard sealant pastes resistant against lubricating oil. Do not use any sealants which harden in order to avoid possible problems at later disassembly. Recommended sealant paste: Loctite 577. Manufacturer: LOCTITE CORPORATION: World Headquarters 705 North Mountain Road Newington, Connecticut 06111 Telephone: 203-278-1280 Telex: 2752-7 Telefax: -28 03 558 LOCTITE UK LTD. Watchmoad Welwyn Garden City . ALT 158 Telephone: 0707-33 1277 Telex: 261277 Telefax: 0707-33 02 33 LOCTITE, EUROPA Ges.m.b.H Akaziengasse 34 A-1232 Wien Telephone: 0222-69 45 21 0222-69 45 30 Telex: 13.3412N ETZSCH 10 DISASSEMBLY AND ASSEMBLY PAGE OF THE ROTATING PARTS 10.5 10.6 Removal and Fitting of the Adapters Where a pump is fitted with adapter (5055) on drive shaft (1005) or connecting shaft (1050) this may be removed as follows: ‘© Drive the pin (5070) out of the adapter (5055) Now pull the adapter (5055) off the drive shaft (1005} or connecting shaft (1050). Remove the O-ring (8065). Refitting is a simple reversal of the procedure. When refitting please observe the following note: Secure the pin (5070) after installing into adapter {5055} against dropping out by each one punch mark ‘on both side of the adapter (5055) at the edge of the bore hole, ses 5055N ETZ5 CH 11 DISMANTLING AND ASSEMBLY PAGE OF THE BEARINGS 11.0 11 Disassembly and Assembly of _ the Bearings 11.1 For drive shaft removal @ Remove key {1010} + Ifan adapter (5055) exists and had not yet been removed together with joints: Removal of adapter according to ~ Page 10.3, Section 10.3 with pin joints. ~Page 10.5, Section 10.6 with gear joints. Remove stuffing box housing (7015) from bearing housing (0005) and slip off from drive shaft (1005). 1@ ~» For pumps equipped with a different type of shaft sealing, with for instance a mechanical seal, please follow the Instructions under Sections 7 and 12 Remove thrower (7111) from the drive shaft (1005} Remove lip seal (0030) and substitute a new one every time during refitting. # Then remove circlip (0135) as well as second spacer ring {0065/2} Press drive shaft {1005} with roller bearings (0020, 0110) out of the bearing housing (0005) or apply a standard pullerdevice. Press lip seal (0041) out of the bearing housing (0005) and substitute a new one every time during refitting.PAGE 11 DISASSEMBLY AND ASSEMBLY 11.0R OF THE BEARINGS 11.2 For removal of bearings from drive Shaft: © Remove circlip (0035). Remove first spacer ring (0055/1). ‘+ Pull roller bearing (0110) off from drive shaft (1005). Remove grease retaining ring {0050} and second ‘spacer ring (0055/2) @ Remove circlip (0315), grease retaining rings (0310) and also shim rings (0027) and {0028) ‘Remove first spacer ring (0065/1), # Pull roller bearing (0020) off from drive shaft (1005). Continued on Page 11.1N ETZS CH 11 DISMANTLING AND ASSEMBLY | PAGE _—s OF THE BEARINGS 11.1 11.3 For pre-assembly of drive shaft: con ‘Heat up roller bearing (0020) to about 100°C. e.g. ona cooktop, # Spread trade recommended “antistick paste” on drive shaft [1005] bearing seats to avoid frictional corrosion, also for easier demounting later on. Please wear heat-proof gloves! Push roller bearing (0020) up to shoulder (AJ on to Grive shaft (1005) ‘ Apply grease on to both sides of roller bearing (0020). Fill all hollow spaces From the drive side, slip first spacer ring (0065/1) over drive shaft (1005) and place on roller bearing (0020) Push shim rings (0027) and (0028), also grease retain- ing ring {0310}, until they touch the inner raceway of the roller bearing (0020) on drive shaft (1005). Pay ‘attention to correct orientation of grease retaining ring {0310}. : Push circlip (0315) until it touches the grease retaining ring {0310} on drive shaft (1005) and snap it into its groove all around. ‘Slip frst spacer ring (0055/1) over drive shaft {1005} Until it touches the smaller shoulder (B). Slip grease retaining ring (0050} over drive shaft (1005) Until it touches the first spacer ring (0055/1). Pay atten- tion to its correct orientation, Please compare sectional drawing NM...! Continued on Page 11.18 > v2 =>, t Sy 0065/1PAGE 11 DISASSEMBLY AND ASSEMBLY 11.1R OF THE BEARINGS Heat roller bearing (0110) up to about 100°C, e.g on a cooktop. © Spread trade recommended “antistick paste” on drive shaft (1005) bearing seats to avoid frictional corrosion, also for easier demounting later on. Aa Please wear heat-proof gloves! © Push roller bearing (01 10} over drive shaft (1005) unti it touches the grease retaining ring {0050). Apply grease on roller bearing (0110). Fill all hollow spaces! # Place second spacer ring (0055/2) until it touches the roller bearing (01 10) on drive shaft (1005). # Place circlip (0035) on drive shaft (1005) and push unti it touches the second spacer ring {0055/2} on drive shaft (1005) and snap into its groove all around. Before fitting preassembled drive shaft (1005} into the bearing housing (0005), the shaft must be totally cooled. 11.4 For fitting pre-assembled drive shaft into bearing housing: Spray anti-corrosion oil (as commercially available) on the inside of bearing housing (0005) and heet for instance in the waterbath to a temperature of 50 - 70°C. Thoroughly prepare all subsequent activities and carry through without delay! The bearing housing A {0005) should not coo! off too much, otherwise the fitting of the bearings might become difficult! Please wear heat-proof gloves! © With the drive side (Aj at the bottom, place vertically and clamp bearing housing (0005) in a vice, or support it on wooden blocks. At the drive side (A) of bearing housing (0005), there should be ample space for the protruding ‘end of drive shaft (0005) by means of compressed air and again treat inside with anti-corrosion oil. Continued on Page 11.2 17 = ono 0050 1005 1008;NETZSCH 11 DISASSEMBLY AND ASSEMBLY PAGE ad OF THE BEARINGS 11.2 + Insert pre-assembled drive shaft (1005) with roller bearings (0020, 0110} from above into bearing housing (0005) until it couches the stop of roller bearing (0020) at first spacer ring (0065/1) Do not interrupt this “insertion” procedure! For bigger pumps [size NM 063...and larger) use a crane. # Place second spacer ring (0065/2) on roller bearing (0020), Insert circlip (0135) into bearing housing (0005) and snap it into its groove all around, ‘@ Insert a new lip seal (0030) into bearing housing (0005) Pay attention to correct orientation, The spiral ring must point to the inside of roller bearing (0020). Compare sectional drawing NM. © Push thrower (7111) on to drive shaft (1005) ina distance of about 5 to 10 mm to bearing housing (0005) @ Place pre-assembled stuffing box housing (7015) with inserted front/rear packing (7040, 7045} on to drive shaft, (1005) and insert into bearing housing (0005). For pumps equipped with a different type of shaft m3 | sealing, with for instance a mechanical seal, plea the instructions under Sections 7 and 12. @ Insert lip seal (0041) into bearing housing 0005}. @ Take care of correct orientation. The spiral ring must point to the inside of roller bearing (01 10). Compare section drawing NM...! ® Fitin key (1010) # Ifan adapter (5055) exists: Fitting of the adapter according to — Page 10.3, Section 10.3 with pin joints. Page 10.5, Section 10.6 with gear joints.$900 $000 €Z00 £200 5900 000 ao ofofolefofofals ay Jequinn Guyer 0z00 Selo OLL0- 0s00 0€02 SZ0Z 0Z0Z 8661 OLo8 sloz Log OL0€ S€02 , SLOE BA TEM mmf; FRE H Osog 0902 S502 Sr0Z , 6661 SODE S00Z M102 ZLOB SOO OLOL 000 stog 4 a stout 23thjuss LUlololels[ol5] ag) “PPO TF roquinny Buynesa so SAAS ASST INP K DOES OSS ¥ SAN 2 oa] 9105 ovos S908 S208 5505 0£0S S805 Sols 980s B66t14 RECOMMENDED STOCK PAGE OF WEAR PARTS 14.0 14 Recommended Spare Parts (Pump with gear joints with ‘SM-protecting bellow) In general, we have all spare parts in stock. Our subsidiaries and exclusive representatives also hold a certain stock. For special cases and when short waiting periods are not acceptable, we recommend to keep an amount of spare parts, corresponding to the pump, in stock on site as follows: Pieces Position Designation Large smal | Number set set 1 1 3005 stator a 1 8015 O-ring 1 5 1999 rotor 2 A 5015 complete gear joint 2 2 8021 sMseal 2 2 8025 O-ring 2 2 5105 O-ring 2 2 5106 O-ring 1 1 806s o-ring ee eee dr || c0as O-ring 2 2 5086 SM-protecting bellow 16/24) 5035 jl head screw *) 16 pieces for joint basic size NM...45 to NM...63 24 pieces for joint basic size NM...76 to NM...105, (joint basic sizes see Section 7.3) To avoid mistakes in delivery, please identity the parts by their position number shown in the spare parts list or on the sectional drawing, Continued page 14.08 [ae Tame signed Tesi Tasued [191255 Mangal “substitute forthe sue approved [2o1235, Hanisch dated released Taree Tanto