Heavy Duty Gear Pumps / AERN Series Pumps

AERN Series

INDEX

Chapter Page No.

1 Introduction 1

2 Performance Characteristics 5

3 Operation 8

4 Shaft Sealing 16

5 Installation 17

6 Routine Maintenance Instructions 23

7 Trouble Shooting 24

8 Parts List 26

9 Assembly & Disassembly Instructions 27

10 Dimension Drawing 35

11 Warrantee & Test Certificate 36

Introduction1

1.1 GeneralThis instruction manual contains necessary information on the AERN series pumps having pump model of AERX, AERN & AERB and must be read carefully before installation, service and maintenance. The manual must be kept easily accessible to the operator.

ImportantThe pump must not be used for other purposes than recommended and quoted for without consulting the company or your local distributor.

Liquids not suitable for the pump can cause damages to the pump unit, with a risk of personal injury.

1.2 Reception, handling and storage1.2.1 ReceptionŸ Remove all packing materials immediately after delivery. Check the consignment for

damage Immediately on arrival and make sure that the name plate/type designation is in accordance with the Packing slip and your order.

Ÿ In case of damage and/or missing parts, report immediately to the carrier at once. Notify your supplier.

Ÿ All pumps have the serial number stamped on a name plate.

1

1

1.2.2 HandlingŸ Check the weight of the pump unit. All parts weigh-

ing more than 20 kg must be lifted using lifting slings and suitable lifting devices, e.g. overhead crane or industrial truck. See section 10 Weights.

Ÿ Never lift the pump unit with only two fastening points. Incorrect lift can cause personal injury and/or damage to the pump unit.

Ÿ Always use two or more lifting slings. Make sure they are secured in such away as to prevent them from slipping. The pump unit should be in a straight fashion.

Introduction

2

1

1.2.3 StorageŸ After receipt of Material and inspection if the pump is not to be installed

immediately the pump should be re-packed and placed in suitable places.

The following points should be noted:Ÿ Cover the pump with corrosion inhibiting treatment material.Ÿ Storage location free from, dust, moist and vibration free place. Ÿ Rotate the pump unit by hand weekly, to prevent jamming and damaged.

1.3 SafetyŸ The pump must not be used for other purposes than recommended and

quoted for without consulting the company or your local distributor.Always wear suitable safety clothing when handling the pump.

Ÿ Anchor the pump properly before start-up to avoid personal injury and/or damage to the pump unit.

Ÿ Check to see that the pump can be drained without injuring anyoneand without contaminating the environment or nearby equipment.

Introduction

3

1

Ÿ Make sure that all movable parts are properly covered to avoid personal injury.

Ÿ All electrical installation work must be carried out by electric personnel.Ÿ Improper installation can cause fatal injuries.Ÿ Dust, liquids and gases that can cause overheating, short circuits, corrosion

damage and fire must be kept away from motors and other exposed equipment.Ÿ If the pump handles liquids hazardous for person or environment, some sort of

container must be installed into which leakage can be led. All (possible) leakage should be collected to avoid contamination of the environment.

Ÿ If the surface temperature of the system or parts of the system exceeds 60°C, these areas must be marked with warning text reading "Hot surface" to avoid burns.

Introduction

4

2

2 Performance Characteristics2.1 capacityŸ Drop of capacity with increase in pressure & change of liquid

2.2 suction pressure The identification of suction pressure requirement is significant in any pump application.

Ÿ Its calculation helps to find out the suction lift of the pump, which enables to varify whether the pump will be able to self prime or not.

Ÿ The suction pressure or termed as NPSH ( Net Positive Suction Head ) can be calculated by following equation

NPSH = Atmospheric pressure + Static Head - Static Lift

viscosity

STATIC LIFT ATMOSPHERIC PRESSURE

STATIC HEAD

Performance Characteristics

5

22

2.3 Discharge pressure: Ÿ The discharge pressure shown in the delivery line is nothing but the overcoming

of system pressure created by the resistance of the pipeline and the shearing force of the liquid. Thus it can be said that a gear pump does not develop pressure by its own but work against the system pressure exerted on it.

2.4 Power Consumption:

Ÿ The power consumption of a rotary gear pump is mainly influenced by the differ-ential pressure exerted on it.

Ÿ Factors effecting on power consumption as follows:1. liquid viscosity2. Sp. gravity of liquid.3. Frictional loss.4. operating temperature


6

2

2.5 Effect of Viscosity:Ÿ Viscosity is that property of any liquid which tends to

resist a shearing force. Ÿ The change in viscosity very much affects the perfor-

mance characteristics of the pump i.e. capacity, power consumption and speed.

Ÿ At a defined set pressure the capacity of a pump slightly reduces with decrease in viscosity. This may be due to increase in internal slippage.

Ÿ For a pump running at set speed for the desired capacity, the power consumption increases with increase of liquid viscosity and decreases with the decrease of viscosity.

Ÿ The above curves also show the effect of speed with reference to viscosity.

PO

WE

R C

ON

SU

PT

ION

SPEED

500

SSU

200

SSU

ACTUAL

THEORITICAL

PO

WE

R C

ON

SU

PT

ION

HYDRAULIC HP +VOLUMETRIC LOSSES

POWER CONSUPTION AN NO LOAD =

FRICTIONAL LOSSES

+

MECHANICAL LOSSES

OEFFERNTIAL PRESSURE

CA

PA

CIT

Y

THEORITICAL

500 SSU200 SSU

ACTUAL

OEFFERNTIAL PRESSURE

VOLUME TRIC LOSSES

CA

PA

CIT

Y

THEO

RIT

ICAL

500

SSU

200

SSU

SPEED

ACTUAL


7

3

3.1 Genral Gears

Pump Casing

Seal Drive Shaft

Bearing

R.V. Cover

Relief Valve

Front Cover

Wear Plate

Operation

8

3

3.2 Operating Principal

The external gear pump uses two identical gears rotating against each other one gear is driven by a motor and it in turn drives the other gear. Each gear is supported by a shaft with bearings on both sides of the gear.

1. As the gears come out of mesh, they create expanding volume on the inlet side of the pump. Liquid flows into the cavity and is trapped by the gear teeth as they rotate.

2. Liquid travels around the interior of the casing in the pockets between the teeth and the casing it does not pass between the gears.

3. Finally, the meshing of the gears forces liquid through the outlet port under pressure.

Suction

Suction

Suction

Discharge

Discharge

Discharge

Operation

9

3

3.3 Safety Relief valve:3.3.1 Working PrincipleŸ

valve protecting the pump against overpressure. Ÿ It can be installed on the pump or in the installation.Ÿ This safety relief valve limits the differential pressure (Δp) between suction and

discharge, not the maximum pressure within the installation.For example, as media cannot escape when the discharge side of the pump is obstructed, an over-pressure may cause severe damage to the pump.

Ÿ The safety relief valve provides an escape path, rerouting the media back to the suction side when reaching a specified pressure level.

Ÿ The safety relief valve protects the pump against over-pressure only in one flow direction.

Ÿ The safety relief valve will not provide protection against over-pressure when the pump rotates in the opposite direction.

The positive displacement principle requires the installation of a safety relief

Operation

10

3

Ÿ

properly. Ÿ When the safety relief valve is not installed on the pump, other protections

against overpressure have to be provided.Ÿ If the pump rotates in the opposite direction, the safety relief valve or top

cover must be disassembled and turned around by 180°.

An open safety relief valve indicates that the installation is not functioning

Discharge Suction

Clockwise Direction Anti Clockwise Direction

DischargeSuction

Operation

11

3

3.3.2 Safety Relief valve adjustment:Ÿ

sure is performed at the factory.Ÿ To adjust the Safety Relief valve for oper-

ating pressure, proceed as follows :1. Open the hex cap.2. Tighten the ad. screw for increase

set operating pressure or loose the ad. Screw for reduce the pump operating

pressure.

▲ while increase of operating pressure, power consumption of pump must not exceed the motor rated power.

3. Tighten the hex cap. Make sure that air must leakge from hex cap & ad, screw.

Adjustment of the standard setting pres-

Operation

12

3

3.4 Check list for starting the pump:

3.4.1 Cleaning the pump

Ÿ There may be residual mineral oil inside the pump deriving from the pump testing and the initially lubricating of the bearing bushes.

Ÿ If the lubricating oil is not acceptable for the pumped liquid, the pump should be cleaned thoroughly.

3.4.2 Supply and discharge lineŸ Suction and discharge pipes are cleaned.Ÿ Suction and discharge pipes are checked for leaks.Ÿ Suction pipe is protected to entered foreign bodies.

Operation

13

3

3.4.3 CharacteristicsŸ

Ÿ Pump model see name plate, RPM, working pressure, effective power, working temperature, direction of rotation, NPSHr etc. as per application

3.4.4 Electrical installationŸ Electric motor rating as per application data sheetŸ Electrical installation is complete as per local regulationsŸ Motor voltage corresponds with mains voltage. Check terminal board.Ÿ Motor protection is adjusted properly.Ÿ Direction of motor rotation corresponds with direction of pump rotation.

The characteristics of the pump unit and safety relief valve to be checked.

Operation

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3

3.4.5 Safety relief valveŸ

Ÿ Position of Safety relief valve according to direction of flow.Ÿ The set pressure of the safety relief valve is checked.

3.4.6 DriveŸ Alignment of pump, motor, gearbox etc. is checked

3.4.7 ProtectionŸ All guards and safety devices (coupling, rotating parts, excessive temperature)

are placed.

Safety relief valve (on pump or in piping) is installed

Operation

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4

4. Shaft Seals:

Differnets type of sealing options areaviallable as under.1. Rubble oil seals2. Gland Packing3. Mechanical seal

17 6

4 3

5 2

Mech. Seal

Mech. Seal Part List

1

2

3

5

4

L-RingRotary Face

Stationary Face

Stationary Outer Ring

O"Ring

1

1

1

1

1

6 spring 1

7 Stationary Resting Part 1

Rubber Oil Seal & Gland Packing

Shaft Sealing

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5. Installation:5.1 General:

Pump performance is also dependence on pump installation. This manual gives basic information which is to be observed during installation of the pump. It is important to read this manual by responsible person before installation.

5.2 Location & Foundation:Ÿ Locate the pump/pump unit as close as possible to the liquid source and if

possible below the liquid supply level. The better the suction conditions, the better the performance of the pump.

Ÿ The pump should always be located where it is accessible for inspection, main-tenance and repairing.

Ÿ Every pump should be provide a good foundation by any strong structure to hold the pump rigid and to absorb any strain or shock that may be encountered. If a separate foundation is provided, make it at least 4” wider and longer than base frame.

Ÿ When the unit is placed on the foundation, it should be leveled and checked for position against the piping layout and then fastened Owen.

Installation

17

5

5.3 Alignment:Ÿ

get the required speed.Ÿ The coupling may be direct drive or belt drive. However direct drive is

preferred over belt drive to reduce load on pump drive shaft and bearings.Ÿ During the operation shock load is produce due to pulsation. Therefore,

chose the coupling 1.5 time higher ration than normal constant load.Ÿ Pump and drive unit alignment must not more than as shown in fig.

For running the pump, it is required to couple pump with the drive unit to

Installation

0.2

00

mm

Parralel alignment

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5

5.4 Piping:Ÿ

nection ports of the pump and shortest possible.Ÿ If the fluid to be pumped is high viscous, pressure

losses in the suction and discharge lines may increase considerably. Other piping components like valves, elbows, strainers and filters also cause pressure losses.

Ÿ Diameters, length of piping and other components should be selected in such a way that the pump will operate without causing mechanical damage to the pump/pump unit, taking into account the minimum required inlet pressure, the maximum allowable working pressure and the installed motor power.

Ÿ Check the tightness of the pipes after connection.

Use piping with an equal diameter than the con-

Strainer

PumpIsolation valve

Suction

Installation

19

5

5.4.1 Suction pipingŸ

level, the inclining pipe should rise upwards towards the pump without any air pockets.

Ÿ A too small diameter or a too long suction pipe, a too small or blocked strainer will increase pressure losses so that the NPSHa (NPSH available) becomes smaller than the NPSH (NPSH required).Cavitations will occur, causing noise and vibrations. Mechanical damage to pump and pump unit is not excluded.

Ÿ When a suction strainer or filter is installed pressure losses in the suction line must be checked constantly. Also check if the inlet pressure at the suction flange of the pump is still sufficiently high.

Liquids should enter the pump from a level higher than the pump

Installation

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5

5.4.2 Isolating valvesŸ

Isolation can be done by installing valves in suction and discharge lines.Ÿ These valves must have a cylindrical passage of the same diameter of the piping.Ÿ When operating the pump, the valves must be opened completely. The

output must never be regulated by means of closing valves in suction or discharge pipes.It must be regulated by changing shaft speed or by re-routing the media over a by-pass back to the supply tank.

5.4.3 StrainerŸ Foreign particles can seriously damage the pump. Avoid the entry of these

particles by installing a strainer.Ÿ When selecting the strainer attention should be given to the size of the openings

so that pressure losses are minimized. The cross-sectional area of the strainer must be three times that of the suction pipe.

Ÿ Install the strainer in such a way that maintenance and cleaning are possible.Ÿ Make sure that the pressure drop in the strainer is calculated with the right

viscosity. Heat the strainer if necessary to reduce viscosity and pressure drop.

To allow proper maintenance it is necessary to be able to isolate the pump.

Installation

21

5

5.5 Electrical Installation.Ÿ

Ÿ Input voltage & frequency must be match with operating drive motor.Ÿ Install electrical overload safety device.

Make sure that electrical connection must be properly.

Installation

22

6

6 Routine Maintenance instructions:Ÿ

Ÿ Temperature of pump body should not exceed the operating temperature.Ÿ Check the leakage from suction and delivery line.Ÿ Check leakage from gland packing or shaft seal.Ÿ Check the air leakage from suction and relief valve.Ÿ Check the power consumption.Ÿ Check the temperature of the drive unit.Ÿ Check the alignment of the pump unit.Ÿ Check the axial and radial play of drive shaft

Check the nose of pump, Noise must not abnormal.

Routine Maintenance instructions

23

Suction lift too high. Lower pump or raise liquid level.

Fluid pumped not compatible with materials used

Use optional materials.

No barrier system to prevent flow passing.

Ensure discharge pipework higher than suction tank.

Pump allowed to run dry. Ensure system operation prevents this. Fit single or double flushed mechanical seals. Fit flushed packed gland.

Faulty motor. Check and replace motor bearings.

Pumping element missing Fit pumping element.

Relief valve leakage. Check pressure setting and re-adjust if necessary. Examine and clean sealing surfaces. Replace worn parts.

Relief valve chatter Check for wear on sealing surfaces etc. Replace if necessary.

Probable Causes Solutions

Incorrect direction of rotation Reverse motor.

Pump not Primed.

Insufficient NPSH available. (Cavitation)

Expel gas from suction line and pumping chamber and introduce fluid.

Increase suction line diameter. Increase suction head. Simlify suction line configuration and resuce length. Reduce pump speed.

Fluid vaporising in suction line. Increase suction line diameter. Increase suction head. Simplify suction line configuration and reduce length. Reduce pump speed.

Air entering suction line. Remake pipework joints.

Strainer or filter blocked. Service fittings.

Fluid viscosity above rated figure. Increase fluid temperature. Decrease pump speed. Check seal face viscosity limitations.

Fluid viscosity below rated figure. Decrease Fluid temperature. Increase pump speed.

Fluid temp. above rated figure. Cool the pump casing. Reduce fluid temperature. Check seal face and elastomer temp. limitations.

Fluid temp. below rated figure. Heat the pump casing. Increase fluid temperature.

Unexpected solids in fuid. Clean the system. Fit strainer to suction line.

Discharge pressure above ratedfigure

Check for obstructions i.e. closed valve. Service system and change to prevent problem recurring. Simplify dicharge line to decrease pressure.

Gland over-tightened Slacken and re-adjust gland packing.

Gland under-tightened adjust gland packing.

Se

izu

re

Pa

ck

ed

gla

nd

le

ak

ag

e

Me

ch

an

ica

l s

ea

l le

ak

ag

e

Problem

No

flo

w

Un

de

r c

ap

ac

ity

Irre

gu

lar

dis

ch

arg

e

Lo

w d

isc

ha

rge

pre

ss

ure

Pu

mp

wil

l n

ot

pri

me

Pri

me lo

st

aft

er

sta

rtin

g

Pu

mp

sta

lls w

hen

sta

rtin

g

Pu

mp

ov

erh

ea

ts

Mo

tor

ov

erh

ea

ts

Ex

ce

ss

ive

po

we

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bs

orb

ed

No

ise

an

d v

ibra

tio

n

Pu

mp

ele

me

nt

we

ar

Pump speed above rated figure. Decrease pump speed.

Pump speed below rated figure. Increase pump speed.

Pump casing strained by pipework.

Check alignment of pipes. Fit flexible pipes or expansion fittings. Support pipework.

Flexible coupling misaligned. Check alignment and adjust mountings accrdingly.

Insecure pump drive mountings. Fit lock washers to slack fasteners and re-tighten.

Shaft bearing wear or failure. Refer to pump maker for advice and replacement parts.

Insufficient gearcase lubrication. Refer to pump maker's instructions.

Metal to metal contact of pumping element.

Check rated and duty presures. Refer to pump maker.

Worn pumping element. Fit new components.

Trouble Shooting Trouble Shooting 7

24

10

11

12

13 14

15

16

17

18

19

20

21

22

23

24

25

26

2728

1

2

34

5

67

8

9

25

29

8 Parts List

AERN Pump with Needle Roller bearing as shaft BearingsAERX Pump with Needle Roller bearing as shaft Bearings & V-sealAERB Pump with Bush bearing as shaft Bearings

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PARTS NO.

DESCRIPTIONS AERN PUMP

AERXPUMP

AERBPUMP

Drain oil plug

Bolt, gland cover

washer, gland cover

Gland cover

Shaft Seal

Bolt, Front cover

Washer, front cover

Dowel

Oil inlet plug

Shaft Bearing

V - seal

Wear Plate

Body Packing

Gears

Stator shaft

Rotor shaft

Bearing Sleeve

Snap Ring

Washer, Gear Shaft Assembly

Bolt, Gear Shaft assembly

Pump Casing

R. V. Cover

Hex Cap, Relief Valve

Adjustment screw

R. V. Plug

Spring Sheet

R. V. Spring

R. V. Piston

PARTS NO.

DESCRIPTIONS AERN PUMP

AERXPUMP

AERBPUMP

123456789

1011121314

151617181920212223242526272829 Front Cover

9

9.1 GeneralŸ

tioning, high repair costs and long-term inoperability.Ÿ Disassembly and assembly may only be carried out by trained personnel. Such

personnel should be familiar with the pump and follow the instructions below.Ÿ ANI Engineers is not liable for accidents and damage of the pump or pump unit

for faulty assembly.Ÿ Remove the pump from the operation.

9.2 Dissemble Instructions.

9.2.1 Remove gland coverŸ unscrew hex bolt no.2 & washerŸ Remove gland cover

Insufficient or wrong assembly and disassembly can lead to the pump malfunc-

24

Assembly & Disassembly Instructions

27

9

9.2.2 Remove Front coverŸ

Ÿ Open front coverŸ Remove body packingŸ Remove dowel if inside the front cover.Ÿ Remove V-seal if pump model AERXŸ Remove shaft bearing (Needle roller or bush )Ÿ Remove shaft seal from front cover,no.5

9.2.3 Remove R.V. cover assemblyŸ unscrew hex bolt no.6 & washerŸ Remove R.V. coverŸ Remove body packingŸ Remove dowel if inside the R.V. cover.Ÿ Remove V-seal if pump model AERXŸ Remove shaft bearing (Needle roller or bush )

unscrew hex bolt no.6 & washer

6

6 5

28


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9.2.4 Relief valve disassemblyŸ

find problem in relief valve operation.

Ÿ unscrew hex cap, no.23Ÿ unscrew Adjustment screwŸ Open relief valve plugŸ Remove spring sheetŸ Remove springŸ Remove piston.

Open relief valve assembly if

23


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9.2.5 Remove Gear shaft assemblyŸ

Ÿ Remove rotor and stator gear shaft assembly.

9.2.6 Gear shaft disassemblyŸ Unscrew bolts no. 20Ÿ Remove washers, no. 19Ÿ Remove gears & Bearing Sleeves from

shafts, use the plastic block to avoid shaft must not damage from press force.

Remove wear plates

SUPPORT

PRESS


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9.3 Assembly Instructions.9.3.1 Gear shaft assemblyŸ

hand & second is left hand in pair)Ÿ Insert bearing sleeve both side, replace if

damageŸ Insert washer and screw the bolt no. 20

9.3.2 Gear shaft assemblyŸ Assembled rotor & stator gear shaft

assembly in pump casing. Ÿ Assembled wear plate, replace wear

plates if wear out.Ÿ Replace gasket body packing with seal-

ant.

Insert Gears in the shafts (one gear is right

SUPPORT

PRESS


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9.3.3 Relief valve assemblyŸ

Ÿ Place spring in piston.Ÿ Place spring sheet on spring

Screw the relief valve plug.Ÿ Screw the adjustment screw as previously.Ÿ Screw the hex cap over the adjustments

screw.

9.3.4 Relief valve cover assemblyŸ Fit the bearing in Relief valve cover.

,replace bearing if damagedŸ Fit the V-seal in Relief valve cover if pump

model is AERX. (replace the V-seal if damaged)

Ÿ Fit the relief valve assembly with pump casing.

Ÿ Screw the bolt no. 6 with washer

Place piston in relief valve cover.

6


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9.3.5 Front cover assemblyŸ

bearing if damaged)Ÿ Fit the V-seal in front cover if pump

model is AERX. (replace the V-seal if damaged)

Ÿ Fit the front cover assembly with pump casing.

Ÿ Screw the bolt no. 6 with washer

9.3.6 Pump Rotation Check:Ÿ Checks the drive shaft rotates smoothly,

then fit all dowel and tighten the bolt no. 6.

Fit the bearing in front cover. (replace

6 5


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9.3.7 Gland cover Fitting:Ÿ

(replace the seal if damaged)Ÿ Push the gland cover in to the gland

box.Ÿ Screw the bolt no 2. With washer.

(each bolt should b tighten equally)

Fit the shaft seal in gland cover.

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AE-050-S-M-L

AE-100-S-M-L

AE-150-S-M-L

AE-200-S-L

AE-250-S-L

AE-300-S-L

AE-400-S-L

AE-500-S-L

AE-600-S-L

AE-601-S-L

239

271

318

359

419

461

554

615

690

749

150

160

180

200

220

240

280

295

340

360

110

130

145

165

190

220

255

280

318

357

80

90

105

110

130

160

180

200

220

240

100

110

130

150

160

220

270

300

350

380

91

100

119

133

163

166

189

215

215

230

80

90

100

112

132

160

180

200

225

250

69.0

74.0

80.0

89.5

100.0

131.0

145.0

160.0

178.0

200.0

12

12

14

14

15

20

22

25

26

28

08

10

10

12

15

18

18

19

20

22

4

4

4

4

4

4

4

4

4

4

89

108

127

152

178

190

229

254

279

279

16

16

16

19

19

19

19

22

22

22

60

79

98

121

140

152

190

216

241

241

22

25

25

40

40

53

53

60

70

70

30

30

40

50

55

60

65

85

95

100

11.5

15.0

21.0

24.0

27.0

32.0

37.0

47.0

52.0

57.0

4

5

6

8

8

10

10

14

16

16

13.0

17.0

23.5

27.0

30.0

35.0

40.0

50.5

58.0

61.0

SHAFT DIMENSIONS FLANGE DIMENSIONS MOUNTING DIMENSIONS OVERALL

DIMENTIONS Model

A F H2 B C E H H1 T D ø1No. OF HOLE

No. OF SIZE P.C.D. L L1 Dø P OD ø2 Kg.

Weight

8.0

14.0

22.5

28.0

43.0

59.0

82.0

150.0

175.0

190.0

35

Dimension Drawing

A

C E

H2

L

H

F

B

H1

DØ

2

T

4 Nos D Holes 1 Ø

L1

DØ Q

P

36

11

Desi

gn-P

rinte

d : K

eta

n P

ithva

98255 1

711

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Heavy Duty Gear Pumps / AERN Series Pumps

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Transcript of Heavy Duty Gear Pumps / AERN Series Pumps