Netzsch 2
Netzsch 2
Netzsch 2
Maintenance Instructions
NEMO®-Pump
Model Number
Machine Number
Date of issue
Important Note
These operating instructions • Must be read and applied the national requirements
are designed to familiarize by any person in charge in force for the prevention
the user with the machine of carrying out work with of accidents and the
and its designated use. and on the machine, environmental protection.
The Instruction Manual such as:
In addition to the operating
• Contains important inform-
Operation including instructions and to the manda-
ation on how to operate
setting up, troubleshooting tory rules and regulations for
the machine safely, proper-
in the course of work, accident prevention and envi-
ly and efficiently. Observing
evacuation of production ronmental protection in the
these instructions help to
waste, care and disposal country and place of use of
avoid danger, to reduce
of fuels and consumables the machine, the generally
repair costs and downtimes
recognized technical rules for
and to increase the reliabil- Maintenance (servicing,
safe and proper working must
ity and life of the machine; inspection, and/or repair)
also be observed.
• Must always be available Transport; shall be com-
wherever the machine is in pleted by the end user and
use. authorized personnel with
Safety Sign
Danger to General Public
Safety Sign
Electrical Hazard
Damage to Machinery
Refer to Section 5.0, “Start-up,” before restart- Criteria for the selection of a pump includes:
ing machine/pump.
1. Compatibility between the medium to be
pumped and the materials of all wetted
1.7 Unauthorized Use of pump parts.
Spare Parts and/or
Modifications to the Pump 2. Compatibility between elastomeric
components and mechanical seal faces.
Modifications to the machines and/or its com-
ponents are permitted only with the manufac- 3. The pressure and temperature rating of
turer’s consent. Original spare parts and acces- the pump.
sories authorized by the manufacturer ensure
safety. The use of other components revokes NEMO® Pumps are of positive displacement
any warranty and liability for consequences progressing cavity design, and have the
which may result. potential to generate very high pressure.
A blockage or closure of a valve in the 1. No one other than those involved with
discharge line can cause a pressure rise higher maintenance and repair should have
than the installation can withstand. A access to power supply.
substantial pressure increase can result in the
bursting of pipes and/or damage to other 2. When dismantling the pump, follow the
components of pump or drive systems. instructions for handling the medium
Extreme caution must be used, especially when (e.g.: protective clothing, no smoking, etc.)
dangerous media is present.
3. Before putting the pump back into
Appropriate safety equipment must be installed operation, ensure that all guards and
(i.e.: an emergency stop button, a pressure other safety devices (e.g.: drive belt
relief valve or rupture disc). and coupling protection) are properly
re-installed.
During maintenance and repair work on the
pump, please note the following:
It is 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 hazardous
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.
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.
Was carefully emptied and cleaned, both inside and out, Yes
in preparation for shipment. No
The following additional precautions are necessary with regard to the handling of media
and the disposal of waste:
We confirm the above information is accurate and complete, and shipment will be in
accordance with legal requirements:
Company
Telephone No.:
Fax No.:
Address
Name Date:
Position:
Company Stamp/Signature
PAGE
2 DESCRIPTION AND GENERAL DATA
2.0
Noise Emissions:
Noise level’s 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.
3 PACKAGING, TRANSPORTATION, PAGE
STORAGE 3.0
Use caution when lifting top-heavy pumps. The center of gravity may be
above the points where the lifting gear is attached. If this is 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!
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
the gear box only.
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 moving the pump or unit on wheels, strictly adhere to the following:
◆ 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.
◆ 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 prolonged
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 temporarily 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 air-tight package and protected from light.
Store Room
The environment in which rubber products are being kept must be cool, dry, 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.
◆ Drives
Observe instructions of the drive supplier.
PAGE
4 INSTALLATION INSTRUCTIONS
4.0
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.
4.2 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
(bar)
Example: NM 0 3 1 S Y 0 2 S 1 2 B
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 fluid for the shaft seals are connected before the pump is put into operation.
For more details see Section 7.4!
STATOR
ABL
31 2” 152 3080
38 2.5” 191 3828
45
53 3” 229 4576
63 4” 305 6116
76 6” 382 7612
90
105 6” 458 9152
5 Start-up
NEMO® Progressing Cavity Pumps must be operated with the following
precautions:
◆ Before initial start-up, 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.
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.
6 Temporary Shutdown
◆ Following the temporary shutdown, the pump should be emptied and
rinsed when:
◆ Stator:
When stored for an extended period, the elastomer along the contact line
between the rotor and stator may become temporarily 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 air-tight
package and protected from light.
◆ Rotor:
◆ Stand-by Pump:
7 Maintenance
7.2 Lubrication
◆ It is advisable to change the oil and check the seals of the pin joints:
NM 003-011 1 0.0338
NM 015 1.5 0.05
NM 021 2 0.067
NM 031 5 0.17
NM 038 15 0.51
NM 045 22 0.75
NM 053 36 1.22
NM 063 78 2.64
NM 076 165 5.60
NM 090 205 6.93
NM 105 450 15.20
8235
Lubricating Oil:
Industrial Designation
Permitted Product
Application DIN 51502
CLP
“SHELL” Omala 460
460
(or equivalent)
General
Industry
with SM-pin joint seal
(8235) of EPDM prescribed:
CLP PG KLUBERSYNTH
320 GH 6-320
PAGE
7 MAINTENANCE 7.3
Before Operation, determine whether the gland housing is equipped with flush
connections or grease zerk and lantern ring (7050).
When choosing option 3.), a discharge line should be connected opposite the
flush feed.
If, for any reason, none of the options above can be applied, the gland housing
connections must be plugged and sealed air-tight. This is necessary to eliminate
air passage through the gland housing during pump operation.
If leakage occurs around the outer edges of the gland housing, the pump
should be stopped and the packing compressed. After compressing the
packing, loosen the packing gland and repeat run-in procedure.
The ring length (Lm) is determined by the shaft diameter (d) and the packing
width (s) under the following formula:
Lm=(d+s) ˙ X ˙ π (in.)
X=tolerance
X=1.10 for shaft diameter ≤ 2.375”
X=1.07 for shaft diameter ≤ 4.00”
X=1.04 for shaft diameter > 4.00”
These are mean values, which may vary with specific packing grades and types
of application.
Example:
Shaft Diameter d=2.375”
Stuffing Box Diameter D=3.15”
Packing Width s:
s= (D - d) / 2= (3.15 - 2.375) / 2= .3875 in.)
Cutting Length Lm:
Lm= (d + s) ˙ 1.10 ˙ π= (2.375 + .3875) ˙ 1.10 ˙ π= 9.5 in.
Straight Cuts
It is recommended that the packing be cut straight and at right angles to the
shaft. In order to achieve parallel contact of the cut ends without a gap when
closing the packing ring, the cutting angle on both ends should be about 12-20º.
Continued on Page 7.4R
PAGE
7 MAINTENANCE
7.4R
In conjunction with the straight cut, the result is a slight bracing of the rings
against the gland housing.
Installation
• Carefully twist open the packing rings just far
enough to enable them to be easily slipped over the
shaft. Excessive bending of the packing rings
can cause damage.
• Install each packing ring separately as follows:
- insert into gland housing, cut end first
- insert each packing ring uniformly separating
the cut ends in 90º increments.
• Continue inserting packing rings into the gland housing until the last
packing ring protrudes approximately 1/2 of the width of the packing ring.
• Compress the packing rings into the gland housing by tightening the gland
nuts by hand. Where a lantern ring is fitted, check to ensure that it is
correctly aligned with the connection.
8 Trouble-Shooting
◆ The table helps to identify the problem and offers a possible solution.
For more complicated problems, consult the manufacturer.
CORRECTIVE ACTION
1 Fill pump and turn by hand. If necessary, use glycerine to lubricate stator.
2 Check motor nameplate data. Test voltage, phase and frequency.
3 Measure actual discharge pressure and compare to your specification.
4 Remove debris and correct any damage.
5 If liquid temperature cannot be reduced, use an undersized rotor.
6 Check specified application, If necessary, change stator material.
7 Increase liquid-to-solids ratio.
8 Clean pump and rinse out after each use.
9 Increase NPSHA; eliminate leaks (see No. 10).
10 Check seals; tighten piping connections.
11 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 liquid temperature; install pump at lower elevation.
15 Fill pump; provide dry run protection; relocate suction piping.
16 Replace stator.
17 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 Re-align pump and drive.
21 Replace coupling elastomer; re-align.
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 worn shafts.
27 Change packing material.
28 Reverse polarity of drive motor.
29 Rework or replace seal faces.
30 Replace o-rings; check specified application. Change o-ring material of construction if necessary.
PAGE 9 DISASSEMBLY AND ASSEMBLY
9.0 OF THE PUMP HOUSING
◆ DIsconnect the pipework on the suction side and pressure side of the pump.
◆ Remove the pump housing (2010) from drive stool (0085) or bearing
housing (0005).
Required
torque 70 132 264 396 660 704 880 1056
in/lbs.
10 DISASSEMBLY AND ASSEMBLY PAGE
OF THE ROTATING PARTS 10.0
◆ Push circlip (5065) out of its groove and slip off over
the head of rotor (1999), connecting shaft (1050) or
adapter (5055, 5056).
◆ From the drive side, slip first spacer ring (0065/1) over
drive shaft (1005) and place on roller bearing (0020).
◆ With the drive side (A) 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.
In general, we have all spare parts subject to wear in stock. Our subsidiaries and
exclusive representatives also hold a certain stock. We recommend to keep an
amount of spare parts, corresponding to the pump, in stock on site as follows:
1 1 3005 stator
2 2 8005* gasket
1 1 8015 O-ring
1 – 1998 coupling rod
2 – 5075 pin
2 – 8235 SM-seal
4 – 8060 O-ring
1 – 8065 O-ring
2 – 5065 circlip
1 – 5110 sleeve
1 – 5115 sleeve
1 – 1999 rotor
2 – 5425 clamp ring
To ensure that you receive the part quickly, please provide the following information with
your order. Also, please specify the model number of your pump.
or: 3. Identification number of part (Note: The I.D. Number is a six digit number
which describes the part, pump size, and materials of construction).
* This gasket is only used with rigid material stators (i.e. metal, PTFE, plastics)
Netzsch Incorporated Quality Pays
119 Pickering Way • Exton, PA 19341 ® NEMO: Registered
610.363.8010 • Fax: 610.363.0971 trademark of NETZSCH For Itself
e-mail: [email protected] MOHNOPUMPEN GMBH.
www.netzschusa.com