VERDER PACKO ZL Series Manual

CONTENTS

GENERAL

1.1 General Information 1

1.2 Manufacturer 1

1.3 Copyright 1

1.4

Declaration of conformity

1.5

Intended Use

1.6 Type designation 3

1.7 Sound pressure level 4

1.8 Construction 5

1.9 Packaging & Transport 6

1.10

Storage

2 SAFETY

2.1 DO’S and DON’TS 7

2.2 ATEX safety measures 8

INSTALLATION

3.1 Installation 9

3.2 Adjustment Pressure Relief Valve 9

3.3 Connection of the motor 11

3.4

Connecting

the

mechanical seal flush

3.5

Start Up

4 CHECK THE PUMP ROTATION

4.1 Principle of operation 14

4.2

Direction of rotation

5 OPERATION

5.1 Troubleshooting 15

5.2 Cleaning 16

MAINTENANCE

6.1

Rotor Case

isassembly

6.2 Inspection 18

6.3 Seal Maintenance 19

6.4 Rotor Case Assembly 22

6.5

Rotor Clearance

6.6

Rotor Timing

6.7 Gearbox Maintenance 26

6.8 Lubrication 30

TECHNICAL

INFORMATION

7.1

echnical Data

8 EXPLODED VIEWS

8.1 Exploded view ZL100, ZL200 and ZL300 32

8.2 Exploded view ZL400 35

1 GENERAL

1.1 GENERAL INFORMATION

Thank you for purchasing PACKO products!

This manual for the ZL series Rotary Lobe Pumps describes safe and appropriate operation during

operating and in all life cycles.

This manual contains instructions for installation, operation, disassembly and assembly, maintenance

procedures and troubleshooting.

Read and completely understand this manual to learn how to service these pumps prior to

operating or servicing the product and observe to pay special attention to the warnings.

This manual must always be available at the installation location since no liability will be assumed for any

damage or operational malfunctions arising from non-compliance with these operating instructions.

1.2 MANUFACTURER

PACKO INOX LTD

Cardijnlaan 10

B-8600 Diksmuide

Belgium

Telephone: + 32 51 51 92 80

Telefax: + 32 51 51 92 99

E-mail: pumps@packo.com

1.3 COPYRIGHT

These operating instructions are written to support the installation, the use and the maintenance

of the pump in accordance with the European machinery directive. They are originally written in

Dutch, English, French and German by the manufacturer. All other languages are translations of

the original operating instructions.

PACKO INOX LTD has the copyright on this document. These operating instructions may be

reproduced in full in the operating instructions of the machine or installation in which the pump is

installed and may be used for training personnel who must work on or with the pump. Any other

publication, reproduction in full or parts thereof is prohibited.

Although these operating instructions have been carefully drawn up, they do not however cover all

possible eventualities that can occur during the installation, operation or the maintenance of the

pump. In any event, the pump must not be used for purposes other than those stated when

ordering and for which the pump has been constructed, as this could result in physical damage

and injuries.

1.4 DECLARATION OF CONFORMITY

Declaration of conformity according to annex IIA of the

“Machinery” Directive 2006/42 EC

We,

Packo Inox Ltd

Cardijnlaan 10

B-8600 DIKSMUIDE

BELGIUM

confirm that the Packo pump type ……................................, with serial number ..........................

fully complies with the Directive Machinery and with the (harmonised) standard EN 809,

ENISO12100.

It must be brought to your attention that our product is intended to be built into a machine,

and that, on the basis of the “Machinery” Directive, the complete (compound) machine can

only be applied after matching the stipulations of the European demands.

PACKO Inox Ltd, Cardijnlaan 10, B-8600 DIKSMUIDE, BELGIUM is authorized to make up the

technical construction file.

Date

.............................

Signature:

.............................................................................................................................

Wim Bonte

BU Manager pumps

Packo Inox Ltd

1.5 INTENDED USE

The pump should only be used for pumping the media it was selected for and within the limits

specified in the technical datasheets. Any other application beyond the intended use or conversion

of the pump without written agreement with the manufacturer shall be deemed to be not in

accordance with the intended use.

The pump may only be started up for the first time if it has been ensured that all safety devices

are completely fitted and functional.

If any areas are subject to have the risk of explosion, the relevant explosion-proof designed pumps

should be used.

Intended use also covers compliance with the conditions of operation, servicing and maintenance

specified by the manufacturer.

The pump is only to be put into operation filled with medium to be pumped.

Before starting up ensure that:

- Open the valves on the suction side completely to avoid cavitation and,

- Open the valves on the discharge side completely to avoid exceeding the permitted differential

pressure of the pump

- Discharge-side safety measures should be done (e.g. safety valve) to protect the pump from non-

permitted excess pressure

- Protection against contact for hot, cold and moving parts must not be removed during operation

1.6 TYPE DESIGNATION

The type designation can be found on the pump name plate and also on both the order confirmation

and customer invoice.

Example (an X in the code denotes a special version):

Type: ZL/120-213/114

 ZL: pump series

 120: pump type

 213: Speed of the pump when the motor operates at 50Hz

 11: motor power in kW multiplied by ten (11 = 1.1 kW)

 4: number of poles of the motor

Mat. Code: (TL-120) D37SSVQ

 TL: Lobe type (TL = tri-lobe, BW = bi-wing, HL = heli-lobe)

 120: temperature class of the pump (Deg. C)

 D: type of couplings (D = DIN 11851, B = BSP, E = DIN 2642, F = DIN 2576, R = RJT, S = SMS,

I = IDF, T = Tri-Clamp ISO2852, M = Tri-clamp ASME BPE, O = Tri-clamp ISO, N = ANSI flanges,

V = DIN 11864-1, A = DIN 11864-2)

 37: housing size of the NORD reductor

 S: seal configuration (S = standard single seal, Q = quench)

 S: mechanical shaft seal materials (S = silicon carbide / silicon carbide, T = tungsten carbide /

tungsten carbide)

 V: elastomer materials (E = EPDM, V = viton, M = teflon)

 Q: options (T = pump and motor reducer on trolley, U = pump and motor reducer on trolley with

cover, P = bare pump, Q = pump and motor reducer aligned on base plate, R = pump and motor

reducer aligned on base plate with cover)

Moreover, the year and week of construction, the pump serial number (to be stated when ordering

spare parts), the weight, maximum operating temperature and maximum differential head are also

marked on the name plate.

1.7 SOUND PRESSURE LEVEL

The sound-pressure level of the pump, operating at 50Hz without cavitation measured at 1m is less

than 70dB(A). In order to minimize noise and vibration, no other parts of the machine may vibrate at

the same time as the pump. The best solution is therefore to allow the pump to rest directly on the

concrete floor, or to fit shock absorbers between the pump and the frame of the machine.

1.8 CONSTRUCTION

ZL series Rotary Lobe Pumps can be ordered with bare shaft, i.e. pumps without motor or base

plate.

Or, ordered as a complete unit with drive motor, coupling & guard, base plate (or trolley) and

layout described as below.

Example Layout of pumps with complete unit

① Base plate, ② Drive unit, ③ Coupling & coupling guard,

④ Gearbox, ⑤ Rotor case with inlet & outlet ports, ⑥ Front cover

1.9 PACKAGING & TRANSPORT

ZL series are shipped in non-returnable wooden packaging.

Unpack the pump/unit upon delivery and inspect it for visible transport damage.

Any damage occurred during the transporting has to be immediately reported to the transport

agent after receipt of the consignment. Do not put the damaged products into operation.

The pumps need to be transported and secured with care to ensure no damage is caused. Lifting

equipment (hoist) and load securing straps must be placed with sufficient load capacity.

Make sure you set the pump down on a stable horizontal surface.

Below a picture of the complete unit with drive & base plate is shown as an example.

1.10 STORAGE

If the pumps need to be stored temporarily, they should be preserved under normal environmental

conditions and must not be exposed to the weather for any significant period of time.

Heed below measures when a longer storage period is required.

Protect pumps against dust, dirt, water or any other harmful environmental factors.

1. Coat all non-painted surfaces with acid-free and resin-free grease.

2. Do not grease stainless steel parts and non-metallic parts.

3. Cover all openings of pressure and suction ports.

4. Drain water when using it as flushing/quench medium for the shaft seal.

2 SAFETY

2.1 DO’S & DON’TS

DO read and understand these instructions before installing or using the pump.

DO use PACKO spare parts when replacing a component of the pump.

DO NOT service the pump while it is running.

DO NOT place the pump in an application where the service ratings are exceeded.

DO NOT modify the pump. Modifying the pump creates unsafe conditions and voids all warranties.

DO NOT run the pump at a temperature or differential pressure higher than specified on the

pump nameplate.

SAFETY PRECAUTIONS WHEN INSTALLING THE PUMP

DO use an authorized electrician when connecting the pump.

DO observe the mechanical limits of the pump (refer to the pump performance sheet).

DO earth the base plate of the pump to avoid the potential buildup of static electricity.

DO NOT install a throttling valve in the suction line.

SAFETY PRECAUTIONS WHEN OPERATING THE PUMP

DO: only qualified personnel should operate this pump.

DO NOT start the pump as long as someone is working on or touching the pump.

DO NOT touch the pump or the lines when pumping hot fluids or when performing Clean In Place

(CIP) procedures.

DO NOT run the pump with BOTH the suction inlet or discharge outlet blocked. Running the pump

with the inlet or outlet blocked will cause serious damage to the pump.

DO ALWAYS check the pump rotation with liquid in the pump.

DO NOT run the pump with the front cover removed. The rotors and rotor case could be damaged

or may cause severe injury.

DO NOT operate the pump with removed safety guard or shroud.

SAFETY PRECAUTIONS WHEN SERVICING THE PUMP

DO ensure the pump is cool to touch before performing service.

DO relieve all pressure and drain all fluids from the pump and connected piping before performing

service.

DO ENSURE POWER TO THE UNIT HAS BEEN UNPLUGGED PRIOR TO PERFORMING

ANY PUMP MAINTENANCE OR CLEANING.

DO exercise caution and wear protective clothing when using lye or acid for cleaning.

2.2 ATEX SAFETY MEASURES

Pump

type

Risk

Liquid

Dry running of mechanical

seal

(overheated seal faces are an

ignition source)

Leakage

(inflammable liquid can come into the

atmosphere)

Flooded

suction Pump

Non ignitable

liquid

 Flushed mechanical seal

 or flow monitoring to be

installed by the customer

No danger

Ignitable liquid  Flushed mechanical seal

 or single seal with preventive

maintenance by the customer

The flashpoint of a combustible liquid is the lowest temperature at which sufficient vapor is created

above a combustible liquid so that it can ignite when mixed with air. However, be aware that the

temperature of certain spots on the pump (e.g. the mechanical seal or motor) could be warmer than

the temperature of the circulated liquid. Therefore, if the flashpoint of the liquid is above the

temperature the liquid is pumped but below 135°C, it should also be considered as ignitable when

considering the risk leakage.

Please be aware that if a mechanical seal runs dry, the temperature of the seal faces can rise above

400°C.

Pumps with flushed mechanical seal:

You have to make sure there is a continuous circulation of the flushing liquid and the motor

is stopped immediately in case of lack of flushing liquid. Otherwise the mechanical seal can

run dry and generate dangerous high temperatures. When a quench reservoir is applied, the

level of the flushing liquid in the quench reservoir must be guarded by an ATEX approved

level sensor. If the level becomes too high or too low, the pump must be stopped. The

temperature in the quench reservoir should be guarded by an ATEX approved temperature

sensor. The temperature of the flushing liquid should be kept below 60°C. If necessary an

external cooling system should be used to keep the flushing temperature under 60°C. It is

the responsibility of the end user to use a suitable flushing liquid for the mechanical seals.

The mix of the flushing liquid and the pumped liquid must not create any dangerous or

explosive gasses.

The pump should never run with closed valve.

Pumps with single mechanical seal:

You must monitor the flow (e.g. with an ATEX approved flow sensor on the inlet of the pump).

If there is no flow detected, you must stop the motor immediately.

Leakage of an ignitable liquid is a serious safety risk. The end-user has to evaluate the

consequences of the leak and adjust the check frequency for leak of the mechanical seal. In

case leak is detected, the pump must be stopped and the mechanical seal has to be replaced.

The mechanical seal has to be replaced preventively every 3000 operating hours.

The baseplate of the pump must be earthed in order to prevent a build-up of static

electricity.

The pump must not pump liquids warmer than 108°C.

The pump should not be started before compliance with all these safety measures.

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