Operation and Service Manual

ROTAN PUMP

Type GP, HD, PD, CD, ED, CC, and RT

A/S De Smithske
Tagholm l, DK-9400 Nørresundby Tel. +45 96 32 81 11 Fax +45 96 32 81 49

Manual Language Rev.

T1302 GB 010396
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TABLE OF CONTENTS

1. EC DECLARATION OF INCORPORATION...................................................................... 4

2. GENERAL INFORMATION ................................................................................................ 5

3. TRANSPORTATION/STORAGE......................................................................................... 6

4. PUMP TYPES AND VERSIONS.......................................................................................... 7

4.1 ROTAN IN GENERAL ..................................................................................................... 7
4.2 CONFIGURATIONS......................................................................................................... 8

5. TECHNICAL DATA ........................................................................................................... 10

5.1 SHAFT SEALS ................................................................................................................ 10
5.2 BEARINGS ...................................................................................................................... 10
5.3 HEATING ........................................................................................................................ 11
5.4 OPERATIONAL CONDITIONS .................................................................................... 11
5.5 PROTECTIVE DEVICES................................................................................................ 13
5.6 SETTING DIMENSIONS. AXIAL CLEARANCE ........................................................ 15
5.7 EXTERNAL LOADS ...................................................................................................... 15
5.8 NOISE LEVEL................................................................................................................. 15

6. INSTALLATION................................................................................................................. 16

7. STARTING-UP................................................................................................................... 17

8. MAINTENANCE AND OPERATION ............................................................................... 18

8.1 LUBRICATION............................................................................................................... 18
8.2 SOFT SEAL ..................................................................................................................... 18
8.3 SEALING LIQUID .......................................................................................................... 18

9. REPAIR AND INSPECTION.............................................................................................. 19

9.1 DRAINING THE PUMP ................................................................................................. 19
9.2 PUMP PARTS ................................................................................................................. 20
9.3 MECHANICAL SEAL .................................................................................................... 20
9.4 SOFT SEAL ..................................................................................................................... 20
9.5 SLEEVE BEARINGS ...................................................................................................... 20
9.6 FLEXIBLE COUPLING.................................................................................................. 20
9.7 LOCKING THE PUMP SHAFT...................................................................................... 20
9.8 ADJUSTMENT OF AXIAL CTEARAANCE ................................................................ 21
9.9 ED PUMPS IN PARTICULAR ....................................................................................... 21
9.10 GP PUMPS IN PARTICULAR ....................................................................................... 22
9.11 SPECIAL DESIGN. ....CHD............................................................................................ 22

10. TROUBLE-SHOOTING...................................................................................................... 22

11. SPARE PARTS .................................................................................................................... 23

11.1 ORDERING SPARE PARTS .......................................................................................... 23
11.2 SECTION DRAWINGS OF SPARE PARTS ................................................................. 23
11.3 LIST OF SPARE PARTS ................................................................................................ 27

3
1. EC DECLARATION OF INCORPORATION

DESMI ROTAN, A/S De Smithske, Tagholm 1, DK-9400 Nørresundby, hereby declare that
ROTAN pumps of the types GP, HD, PD, CD, ED, CC, and RT have been manufactured in
accordance with:

- THE COUNCIL DIRECTIVE 89/392/EEC on mutual approximation of the laws of the

member states on machines with special reference to Annex 1 of the directive on
essential safety and health requirements in relation to the construction and manufacture
of machines.

- THE COUNCIL DIRECTIVE 73/23/EEC on mutual approximation of the laws of the

member states on electric equipment intended for the use within certain voltage limits.

Bare shaft pumps with delivered by DESMI ROTAN, must not be put into service unless all
relevant provisions are fulfilled.

Nørresundby 7/12-1994

Jos Nijenkamp
Division manager

4
2. GENERAL INFORMATION

On receipt, please check that the unit is complete and undamaged. In the event of shortage or
damage, the carrier and the supplier must be advised immediately, for the purpose of submitting
a claim.

In accordance with the product liability act it is our duty to draw your attention to
the following risks if the pump is misused.

- It is imperative that the engineers involved in assembling and servicing are familiar with
the current operating and maintenance manual before installing and starting-up the
pump, they must be technically qualified.

- The user is responsible for observing the safety instructions in this manual.

- General safety instructions including local safety and operating regulations do not form
part of the pump manual. The user is fully responsible for complying with these
regulations.

- The erection and the service of ROTAN pumps must be carried out in strict accordance
with existing regulations for mechanical and electrical engineering.

- The pump must only be used in accordance with the operating conditions specified on
customer's order. Any deviation must be with the manufacturer's consent.

- The operating and maintenance manual covers standard designs only. Variants in
construction, erection, operation and maintenance are not included.

- The supplier must be contacted in the event of any necessary information not being
found in the manual.

- The service life and the specified properties of the pump unit are limited by wear,
corrosion, and breakdown dependent on the operating conditions. It is the user's duty to
ensure that regular service is carried out and that parts are replaced as and when
necessary. The pump should be stopped if it is operating abnormally or if there is any
visible damage.

- Installations which can cause personal injury or material damage in the event of
breakdown must be provided with reliable and regularly tested alarm systems and/or
spare units.

- All units which are in contact with foodstuffs must be thoroughly cleaned before use.

- Non-observance of these warnings and operating instructions can lead to complete

breakdown and possibly result in personal injury and material damage.

- The manufacturer is absolved from all responsibility if the instructions in this operating
and maintenance manual are not adhered to.

- If the pump is sent on to a third party, it is absolutely essential that it is accompanied by

this operating and maintenance manual plus operating conditions specified in the order.

5
3. TRANSPORTATION/STORAGE

Do not put your fingers into the suction/discharge ports of the pump when handling
the unit.

The pump must be handled carefully and not exposed to knocks and damage.

Lifting is carried out using stable suspension points so that the unit is in equilibrium.
Lifting straps must not be placed over sharp edges.

Where long storage is envisaged, steps must be taken to avoid corrosion and drying out. This can
cause seizure of the mechanical seal seats, which in turn will cause damage to the seal, when the
pump is started up.

Base coat or top coat is applied on the external - not stainless - surfaces of the ROTAN pumps.

The pumps are usually lubricated with machine oil from the factory; pumps for foodstuffs are
treated with a food approved lubricant.

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4. PUMP TYPES AND VERSIONS

4.1 ROTAN IN GENERAL

The ROTAN pump is a gear pump with an internal idler gear in mesh with a main rotor.
The operating principle is shown below:

The modular design of the ROTAN series allows a large number of pump configurations. It is
therefore possible to adapt the ROTAN pump for a specific duty.

All ROTAN pumps can be provided with a relief valve to prevent the build-up of excess
pressure. Most of the pumps can be fitted with a heating/cooling jacket for the pump section and
shaft seal.

All standard pumps allow reversible pumping, the direction of flow is determined only by the
direction of rotation of the motor.

The pumps are grouped into 5 main series:

HD: Heavy Duty.

Parts in contact with the liquid are manufactured in cast iron and steel.

CD: Chemical Duty.

Parts in contact with the liquid are manufactured in stainless steel.

PD: Petrochemical Duty.

Parts which surround the liquid are manufactured in steel.

HD, CD, and PD are each bare shaft units coupled to a motor and mounted on a common base
plate. Shaft sealing arrangements vary, i.e. stuffing box, a single mechanical seal and double
mechanical seals in tandem or back-to-back.

GP: General Purpose.

The pump end is identical to that of the HD pump, but is direct coupled to a flange
mounted motor. The motor must have the located bearing at the drive end. The GP can
be fitted with a stuffing box or a single mechanical seal.

ED: Environmental Duty - magnetically coupled pump.

Parts in contact with the liquid are manufactured in cast iron, stainless steel or steel.
The pump has a bare shaft and is coupled to a motor and mounted on a common base
plate.

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 4.2 CONFIGURATIONS

The configuration of the pump in question is shown on the nameplate (see 11.1).

1) Pump types 6) Lubrication

GP 'General Purpose', mono block pump in cast iron U Idler bearing and main bearing lubricated by pump medium.
HD 'Heavy Duty' pump in cast iron M Externally lubricated idler bearing and main bearing.
FD 'Petrochemical Duty' pump in carbon steel
CD 'Chemical Duty' pump in stainless steel

ED 'Environmental Duty' pump magnetically coupled, in cast iron, carbon 7) Material codes for idler bearing
steel or stainless steel Code Idler bush Idler pin: GP-HD-PD Idler pin: CD
1 Cast iron Hardened 16 MnCr 5 X8 CrNiMo27 5
2 Bronze Hardened 16 MnCr 5 X8 CrNiMo 27 5
2) Pump sizes 3 Carbon Hardened 16 MnCr 5 X 8 CrNiMo 27 5
26 DN25-1" 4 AJ .oxide Cr.oxide coated Cr.oxide coated
33 DN32 -1 1/4" 16 MnCr 5 X 8 CrN'iMo 27 5
41 DN40-1 1/2" 5 Carbon Al.oxide, polished Al.oxide, polished
51 DN50 - 2" 8 Carbide Carbide Carbide
66 DN65 - 2 1/2"'
81 DN80-3"

101 DN100- 4" 8) Material codes for main bearing

126 DN125-5" Code Bearing bush Shaft: GP-HD-PD Shaft: CD
151 DN150-6" 1 Cast iron St.60.2 X 8 CrNiMo 27 5
152 DN150- 6" 2 Bronze St.60.2 X 8 CrNiMo275
201 DN200-8" 3 Carbon St.60.2 X 8 CrNiMo 27 5
4 Al.oxide Cr.oxide coated St.60.2 Cr.oxide coated
X 8 CrNiMo 27 5

3) Configurations 8 Carbide Coated St.60.2 Cr.oxide coated

E Suction/discharge connections in-line X 8 CrNiMo 27 5
B Suction/discharge connections 90° angel (not standard) 9 Silicon carbide Silicon carbide bush or Silicon carbide bush or
Add: Choice of additional options, see page 7. Cr.oxide coated St.60.2 Cr.oxide coated
Add: Only ED pumps: X 8 CrNiMo275
A Magnetic coupling for pump sizes ED26 -41
G Magnetic coupling for pump sizes ED41 - 66 B Ball bearing St.60.2 Not applicable
H Magnetic coupling for pump sizes ED51 – 81
Magnetic coupling for pump sizes ED81 –101

9) Shaft seals
B Packing cord, teflon-impregnated
4) 2 Mechanical shaft seal, DIN 24960-KU,
- Hyphen Bellow type or O-ring type
22 Double mechanical shaft seal,
DIN 24960-KU, O-ring type

5) Material codes for main parts/wetted parts Only for ED Pumps:

Code Type Casing/Covers Rotor/Idler Shaft /2 2 cm magnet length
1 GP/HD GG-25 GG-25 St.60.2 /3 3 cm magnet length
3 CD G-X 6 CrNiMo 18 10X 8 CrNiMo 27 5X8CrNiMo 27 5 /6 6 cm magnet length
4 PD GS-52.3 GG-25 St.60.2 /8 8 cm magnet length
/10 10 cm magnet length
For ED pumps all material codes may be used.

10) Special configurations

S All special configurations are marked with "S"

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 Configurations (supplement to item 3 of the page before)

M – GP/HD M –PD/HD
Sealing with stuffing box, with or without lantern Sealing with mechanical shaft seal, DIN 24960 – KU, Sealing with mechanical shaft seal, DIN 24960 – KU,
ring for use of external lubrication. Used for high combined with a ball bearing as main bearing. combined with a slide bearing as main bearing.
viscosities and where leakages are allowed. Used where only minor leakages are allowed. Used where only minor leakages are allowed.

MM (tandem)- MMP(back to back) MMW (tandem)-MMPW (back to back) T

Double mechanical shaft seals, DIN 24960 – KU, in Double mechanical shaft seals, DIN 24960 – KU, in Special clearances increase of tolerances used for
tandem or back to back, with main bearing in the tandem or back to back, with main bearing in the liquids with a viscosity above 7,500 cSt. Or a
barrier fluid. Used where no leakages are allowed. liquid. Used where no leakages are allowed. UP to temperature above 150°C
Up to 6 bar differential pressure allowed. 16 bars differential pressure allowed.

D K CHD CHD
Heating jacket on the front cover, often required Heating jacket on the rear cover, often required Combination of special clearances and heating jackets
Prior to start-up when pumping high viscosity prior to start-up when pumping high viscosity together with external lubrication of the
Liquieds and liquids which tend to solidify. liquids and liquids which tend to solidify. This main bearing, used in the chocolate industry.
jacket is also used as a seal cooling jacket.

R Special configurations Lubrication

Safety valve, (single acting lone direction), used to Example: Mounting of a cartridge seal, single or Idler bearing and main bearing externally
protect the pump and the complete installation double, is semi standard. lubricated. Used when pumping non-lubricating
against excess pressures. or high viscosity fluids.

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5. TECHNICAL DATA

5.1 SHAFT SEALS

The ROTAN pumps have three types of shaft seals, viz.

- Soft shaft seal

- Mechanical shaft seal
- Magnetic coupling

The type of seal fitted in the pump is indicated on the nameplate (see 4.2).

5.1.1 SOFT SHAFT SEAL

A packed box requires constant maintenance, a leakage of 10-100 drops per minute being
allowable. If the stuffing box is tightened too much, there will be an increase in frictional heat,
which can cause hardening and increase wear on the shaft.

5.1.2 MECHANICAL SEAL

Mechanical seals are virtually leak-free and require no maintenance. Pumps with mechanical
seals should only be run after bleeding and being filled with liquid because if allowed to run dry
the seal faces of the mechanical seal will be damaged. Self-priming up to one minute's duration
however is allowed.

5.1.3 MAGNETIC COUPLING

The magnetic coupling is leak-free. The magnetic coupling separates the pump from the drive
shaft.

Magnetic couplings are designed specifically for each ROTAN pump so that its performance
corresponds to the specifications called for in the order. The pumped liquid acts as the cooling
agent. Depending on the speed and viscosity the maximum temperature rise of the liquid passing
through the coupling for cooling will be 30°C.

Steps must be taken to ensure that the motor cuts should the magnetic coupling slip because of
overload.

5.2 BEARINGS

As a general rule the pumps are fitted with sleeve bearings, the exceptions being
HD .. EM(see 4.2) and GP .. EM, which are fitted with "sealed for life" ball bearings. These
bearings, items CU and NB (see 11.2) are factory lubricated and need no attention.

The sleeve bearings of the U configuration (see 4.2) are lubricated by the liquid pumped, whilst
the M configuration requires separate lubrication. See item 8.1regarding lubrication.

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5.3 HEATING

Where heating is required for the pump, a heating jacket can be provided for the front and/or rear
cover, configuration D and K (see 4.2).

The heating jackets are designed for a maximum working pressure of 10 bar.

5.4 OPERATIONAL CONDITIONS

The limitations (RPM, pressure, temperature, and viscosity) stated in this section are to be
considered as recommended maximum values as the individual ROTAN pump can have further
limitations, e.g. on account of the medium pumped, the shaft seal chosen and in particular the
motor laid out.

5.4.1 RPM

The maximum RPM of the ROTAN pumps for viscosities below 400 cSt are as follows. In the
event of higher viscosities the RPM is reduced to avoid cavitation.

Pump size Maximum RPM

26, 33, 41 1750

51, 66 1450
81 1200
101 950
126 750
151 600
152 500
201 400

5.4.2 DIFFERENTIAL PRESSURE

The total overpressure (inlet pressure + differential pressure) may not exceed:

- 16 bar for the types 26 - 81.

- 10 bar for the types 101 - 201.

The curves below illustrate maximum permissible differential pressure for ROTAN pumps used
for pure, non-abrasive liquids. NOTE: the exceptions are:

- Configuration "MM" and "MMP" with the main bearing placed between the shaft seals -
maximum pressure 6 bar.

- ED81EH - maximum pressure 8 bar.

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Pump size 26 - 81:

Pump size 101 - 201:

Signature Material of the bearings

______ Bronze/steel
Cast iron/steel

............ Carbon/steel
Ceramic/ceramic
Carbon/ceramic
Carbon/carbide
Carbide/carbide
Silicon carbide/silicon carbide

5.4.3 SUCTION HEAD. NPSH

In order to ensure a cavitation-free pumping, the suction conditions should be such that the
pressure on the inlet side is higher than the NPSH, of the pump at the specific operating
conditions.

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5.4.4 TEMPERATURE

The limitation of the operating temperature is, among other things, dependent on the
elastomers used in the pump.

NBR - Nitrile approx. ÷ 30 / + 70°C

FPM - Viton approx. ÷ 25 / +170°C (maximum 135° C in water)
PTFE - Teflon approx. ÷ 15 / +170°C

Pumps with standard clearances are limited to a maximum temperature of 150 °C.

The HD, CD, and PD types provided with special clearances (the configuration includes
a "T" - see 4.2) can in certain cases be used up to 300"C.

The ED pumps must not be exposed to a temperature exceeding 250°C, including the
temperature rise in the magnetic coupling - see subsection 5.1.3; Viton is standard elastomer.

5.4.5 VISCOSITY

ROTAN pumps in standard configurations can be used in the viscosity range 1-7.500 cSt. In the
event of special clearances (T forms part of the designation - see 4.2) the HD, CD and PD types
can be used up to 75.000 cSt; the ED type is limited to 10.000 cSt.

5.5 PROTECTIVE DEVICES

The unit should be provided with suitable protective measures so that pump and motor are not
loaded beyond the limits stated in the order.

5.5.1 RELIEF VALVE

As a result of the ROTAN pump operating against a closed discharge outlet an unlimited
pressure build-up can occur. This means that the pump, piping, and valves etc. should be
protected by a ROTAN relief valve as a minimum safeguard.

The relief valve leads the pumped liquid from the discharge side back to the suction side when
the set pressure is exceeded. The pump must not operate in "by-pass" mode for a long time, as it
will cause heating of both liquid and pump.

The standard relief valve (configuration R) only protects in one pumping direction. The adjusting
screw of the relief valve should point to the suction side of the pump. In the case of a valve with
a vertical adjusting screw, it shall point to the pressure side of the pump. Normally the valves are
provided with a "p" for pressure side and a "s" for suction side.

The opening pressure should be 1-3 bar over the normal operating pressure.

The adjustment of the safety valve from factory may appear from the order. If the valve is
readjusted, the adjusting screw must be re-wrapped in thread tape.

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 Setting dimensions for the relief valves are shown in the following chart.

OPENING PRESSURE BAR

ROTAN TYPE
VALVE NO. 2 4 6 8 10 12 14 16
SETTING MEASURE A mm.
3891,3931,5665 12 8
HD, GP, ED
2286,2287,5666 14 13 11,5 10
26, 33, 41
3656,3657,5667 15,5 14 13 11,5
3475,5307 11,8 9,1
CD, PD, ED
4415,5668 11 8,7 6,5 4,3
26, 33, 41
3770,5509 10 9 8 7
3865,5669 22,5 12,5
HD, GP, PD, ED
2288,5308 25,5 19,5 13,5
51, 66
3658,5518 24,5 22 19,5 16,5 14
3407 27,5 20,5 13
CD, ED
4377 21,5 17,5 13,5
51, 66
3943 19,5 16 13 10
3628,5670 11 0
HD, GP, PD, ED 1969,5309 12,5 6
81, 101 3654,5387 14 10,5 6,5
3727,5671 14,5 12 9,5
4378 21,5 7
CD, ED 3448 28,5 20,5 12,5
81, 101 4379 28,7 24,8 21 17,1
4380 23 20,4 17,7 15
HD, PD, ED 2290,5310 41,5 30 19
126, 151 3276,5672 34 28 22
CD, ED 4680 40 27 14
126, 151 5475 31,5 24,5 17,5
HD, PD, ED 2291,5673 62 55 47
152, 201 3659,5674 49 45 41

CD, ED 4381 61 52 43
152,201 4382 50 45 40 35

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 5.6 SETTING DIMENSIONS. AXIAL CLEARANCE

The axial clearance is the distance between the rotor/idler and the front cover. See section 9.8
regarding adjustment. Setting dimensions are seen from the table below.

Pump size 26/33 41 51/66 81/101 126/151 152 201

Normal axial. 0,10 0,10 0,15 0,20 0,30 0,35 0,40
tolerance *) 0,125 0,15 0,20 0,25 0,375 0,45 0,50
Pumps with spec. 0,20 0,20 0,30 0,40 0,60 0,70 0,80
clearances **) 0,25 0,30 0,40 0,50 0,75 0 0,90 1,0

*) Pumps made of stainless steel are adjusted with a clearance 0.10 mm bigger than stated.

**) The configuration of pumps with special clearances includes a "T" or "CHD" (see
subsection 4.2).

5.7 EXTERNAL LOADS

Permissible force and torque loads on the pump flanges.

Pump Force i N Torque i Nm

size
Px Py Pz MX My Mz
26 630 460 350 28 45 50
33 630 460 350 28 45 50
41 1090 980 850 93 120 120
51 2180 1570 1390 175 260 275
66 2180 1570 1390 175 260 275
81 3400 2450 2160 330 500 520
101 3580 2580 2460 460 650 670
126 6450 5050 4070 950 1200 1500
151 7500 5600 4500 1200 1850 1950
152 11600 8250 6650 1950 3150 3450
201 10500 8400 6650 2450 3650 3850

If ROTAN pumps with free shaft end are required to be belt-driven, information on the
permissible load allowed on the output shaft can be given on request.

5.8 NOISE LEVEL

The A-weighted sound pressure level of the ROTAN pumps dependent on the pump size and the
RPM is seen from the following graph. Other parameters affecting .the sound pressure level are
the differential pressure, the viscosity as well as the manner of installation.

The dB(A) curves in question are based on measurements made during the pumping of mineral
oil with a viscosity of 75 cSt and at a differential pressure of 5 bar.

15
6. INSTALLATION

The following should be considered to avoid operating problems:

Erection:

- The base must be such that the unit is solidly supported and is not pre-stressed when
erected.

- There should be sufficient space around the pump for service. Below is stated the
minimum distance to a wall to enable dismantling of the front cover.

Pump size 26 33 41 51 66

V mm. 50 60 65 70 80

81 101 126 151 152 201

100 115 140 165 180 215

- The suction height of the pump (see 5.4.3) should be taken into consideration.

- Normally the pump is mounted horizontally. If the pump is placed with the flanges
up/down, it will not self-prime. Normally the pump must be installed so that the shaft is
horizontal.

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 Pipework:

- All pipework must be free of any contamination.

- Plugs in the connecting branch of the pump must be removed.

- The pump must be installed in such a way that stresses in the pump casing caused by the
pipework are kept to a minimum. Permissible loads on the pump flanges appear from
subsection 5.7.

Mounting pump and motor:

- Alignment of pump and motor is to be checked after the installation. Procedure is

described in subsection 9.6.

- Check that the pump shaft rotates easily and regularly.

- The coupling between motor and pump is to be completely guarded.

Wiring:

- The wiring is to be carried out by an authorised electrician in accordance with local

regulations.

- Check suitability of voltage available with that on the motor plate.

- The motor overload switch is to be set at the maximum rated current of the motor.

- Check direction of rotation of the motor. If the direction of rotation of the motor is
clockwise then the flow direction is from right to left seen from the motor side.

Relief Valve:

- Check that the valve points in the correct direction (see 5.5.1).

Control:

- The control equipment is to be adjusted and checked.

7. STARTING-UP
Because of the sleeve bearings and shaft seals, ROTAN pumps can only be permitted to run
without a flow of liquid for the short period of self-priming. The faces of the sleeve bearings and
shaft seals must not be allowed to become dry during prolonged storage.

When starting-up, please check:

- that shut-off valves on the inlet and outlet sides are open.

- that on first start-up the pump casing is filled with a small quantity of liquid to ensure the
self-priming ability.

- that cooling/lubricating devices etc., if any, are operational.

- that the control equipment functions.

17
 - that the direction of rotation is correct. If the direction of rotation of the motor is
clockwise, then the flow direction is from right to left seen from the motor side.

- that the pump is drawing the liquid.

- that the pump does not vibrate or is noisy.

- that the pump does not leak.

- that a soft seal, if any, leaks 10-100 drops a minute - see section 8.2.

- that the relief valve opens at the required pressure.

- that stuffing box and bearings do not give overheat; lip seal rings will normally cause a
heating of the shaft during the time of running-in the ring (approx. 2 hours).

- that the operational pressure and power consumption are correct.

- that on the magnetic coupling pumps, slip does not occur (no flow), and that the
temperature rise does not exceed 30°C.

8. MAINTENANCE AND OPERATION

Operating conditions under section 7 should be checked regularly.

8.1 LUBRICATION

ROTAN pumps in configuration M (e.g. HD41ER-IM22B) demand external lubrication of the

slide bearings. The intervals of re-lubrication and the type of lubricant are dependent on the
operating conditions; ask the supplier for particulars.

8.2 SOFT SEAL

Packing cord as shaft seal demands current adjustment to ensure correct leakage at the stuffing
box.

Dependent on RPM and viscosity the stuffing box must leak 10-100 drops a minute to remove
the friction heat generated between shaft and packing cord. In the event of insufficient leakage
the heat generation will cause hardened packing rings and increased wear on the shaft.

8.3 SEALING LIQUID

Systems of sealing liquid in connection with double mechanical seals (configuration MM) must
be checked regularly to ensure

- that the liquid level in the sealing liquid container is correct.

- that the concentration of the pumped medium in the sealing liquid does not overstep the
permissible quantity.

18
 - that the circulation of the sealing liquid between container and stuffing box is in
order.

- that in the case of "back to back" (configuration MMP) the pressure of the sealing liquid
is higher than that of the pumped medium on the primary shaft seal.

8.4 DRY RUNNING

The slide bearings and the shaft seal of the ROTAN pump are usually lubricated by the pumped
liquid, and that is why dry running must not occur.

The lubricating properties of the pumped liquid decide how long the pump may run without
liquid during priming and draining of the system.

9. REPAIR AND INSPECTION

Before attempting any work on the pump ensure that it cannot be started
accidently or unintentionally.

The system must be completely de-pressurized and drained for liquid.

The service engineer must know which liquid has been pumped as well as which
precautions he must take when handling the liquid in question.

In connection with the servicing of magnetically coupled pumps it should be

considered that the magnetic parts can cause damage to pacemakers, credit cards,
floppy disks, computers, and watches.

All precautionary measures, such as coupling guards, pressure relief devices, and
insulation for wiring, must be in place before the pump unit is restarted.

Pump construction appears in subsection 11.2 sectional drawings.

9.1 DRAINING THE PUMP

When the pipe work has been drained, some liquid will remain at the bottom of the pump and in
the stuffing box.

The pump can usually be drained by dismantling the front cover or by placing the pump with the
suction/discharge ports upside down and rotating the shaft.

However, it can be difficult for very viscous liquids to pass from the stuffing box and the
chamber between rotor and rear cover on to the pump casing; in such cases the stuffing box and
the rear cover are fitted with draining devices.

On ED pumps the liquid in the canister is removed through the plug (item MB).

Where toxic liquids are pumped, precautions should be taken before dismantling,
e.g. circulating neutralising liquids in the pump or using safety clothes and a
breathing mask.

19
9.2 PUMP PARTS

The rotor, idler, pump casing, front cover and idler bearing can be inspected merely by removing
the front cover. There is no need to remove the pump from the installation.

Place the idler so that the smaller root diameter faces the front cover.

The front cover should be placed so that the crescent is at the bottom of the pump.

The replacement idler pin is secured by an adhesive to ensure tightness.

9.3 MECHANICAL SEAL

Before replacing the mechanical seal and prior to dismantling, the position of the rotating parts
on the shaft should be measured and noted so that the new seal can be fitted correctly.

9.4 SOFT SEAL

To replace the above, the packing gland is dismantled, and the packing rings are removed with an
extractor. New packing rings can be obtained already formed or they can be produced in the
following way:
Packing cord of the correct size must be wound round the shaft a number of times appropriate to
the number of packing rings and cut through along the shaft with a sharp knife. The packing
rings must be placed in the stuffing box with the slits diametrically opposite and pressed together
using the packing gland. See section 8.2 regarding adjustment.

9.5 SLEEVE BEARINGS

The sleeve bearings must be lubricated when assembling, as they will not withstand dry
operation. The lubricating groove, if any, in the idler pin should face the crescent. The
lubricating groove in the main bearing should be turned upside down.

9.6 FLEXIBLE COUPLING

The HD, CD, PD, and ED pumps are coupled to the motor by means of a flexible coupling. The
alignment between the pump and motor must be checked by means of a straight edge over the
coupling halves at 2 or 3 points on the coupling. Any misalignment, will appear as a gap between
the straight edge and the coupling flange. A feeler gauge must be used to check that the gap is
constant all the way around the coupling. Permissible clearances for eccentricity and parallelism
appear from the supplier's instructions. For correct alignment of the motor and pump suitable
shims must be fitted between the base of the pump and motor and the base plate. Inaccurate
alignment of the pump and motor will result in increased wear on the coupling elements.

9.7 LOCKING THE PUMP SHAFT

On disassembly/assembly it may be necessary to block the pump shaft. This is done by means of
a piece of wood or soft metal placed between the teeth of the rotor through one branch of the
pump.

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9.8 ADJUSTMENT OF AXIAL CTEARAANCE

The axial clearance is checked with a feeler gauge between rotor/idler and front cover. Access is
gained through one of the connection branches of the pump. Setting dimensions are shown in
sub-section 5.6.

If the pump is in situ, the following method of adjusting the axial clearance can be used, a feeler
gauge is not necessary. Adjust the pump shaft so that the rotor touches the front cover, and then
adjust the clearance between the rotor/idler and front cover using the adjusting screws in
accordance with the following table:

Axial clearance ´ 360

Angle change in ° =
pitch

Thread M5 M6 M8 M10 M12

Pitch 0,8 1,0 1,25 1,5 1,75

Regarding types HD, CD, and PD the clearance is adjusted by means of the bearing covers, items
CS and CR. Ensure that the screws, item CT, are tightened crosswise so that the bearing will be
pushed squarely into the housing.

The axial clearance of the GP pump is adjusted by means of the sleeve coupling, item DB,
between pump and motor shaft by means of the adjusting screws, items KX and KY, which are
adjusted crosswise.

For adjustment of the axial clearance of the ED pump the front cover is displaced axially by
means of the screws, items E and NM. It is recommended that the clearance is checked at a
minimum of 3 points to ensure that the front cover is parallel to the rotor.

After the adjustment is made, check that the pump shaft rotates easily and regularly.

9.9 ED PUMPS IN PARTICULAR

The separation of the pump end (the screw joint, item ME) should be done with great care as the
magnets in the external magnetic rotor (item MM) are easily damaged by scratches.

The pump is provided with two threaded holes and two clearance holes in the lower part of the
rear cover (item BA) and the coupling housing (item CQ) respectively. By means of two
threaded bars the pump and the coupling part can thus be pressed from each other, the foot of the
pump casing being fixed to the base, and the foot of the coupling housing sliding on the base,
guided by the threaded bars. The coupling housing is pressed as far back that the outer magnet
(item MM) is completely free of the canister (item MJ). The same procedure is followed during
assembly.

Alternatively disassembly/assembly can be done by using a block and tackle. The pump must be
mounted vertically on its end and the coupling part lifted using an eye bolt in the shaft end.

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 Never put your fingers between the coupling part and the pump part during the
assembly because the magnets will draw the parts together with great force.

Initially the front cover is set to a distance of 2 mm from the pump casing to allow a clearance
between rotor and front cover during the assembly.

The torque of tightening for the bolt, item MP, fixing the shaft in the main bearing, is:
- 10 Nm for coupling type A.
- 30 Nm for coupling types G, H, I; Check that the disc spring, item NG, is correctly
turned.

Take care that the magnetic parts do not pick up metallic shavings.

9.10 GP PUMPS IN PARTICULAR

The flanges motor of the GP pump must be provided with a locked bearing at the drive end to
ensure that the axial clearance of the pump is kept within the permissible limit.

9.11 SPECIAL DESIGN. ....CHD

The HD and CD pumps for pumping chocolate (re. stuffing box see section 11.2) have been
designed so that the main bearing (item BC) is removed from the shaft seal housing along with
the packing gland (item BB). Then the packing gland is separated in two parts and removed,
whereupon the main bearing can be pulled back on the shaft. Now there is free access to pulling
out the packing rings by means of a packing extractor, and to fit new rings in the shaft seal
housing.

10. TROUBLE-SHOOTING

The following list makes it possible to locate failure causes:

Failure Possible cause

-The pump is not self-priming 1-3-4-8-9-13 1. Too high a vacuum

-The pump is unable to
maintain flow
-The capacity is too low
-Noisy pump operation
-Overloading of motor
-The pump becomes jammed
-The pump is subject to
excessive wear
2. Cavitation
1-5 3. Too high a viscosity
2-3-5-7-8-9-13 4. Too high a temperature
2-5 5. The Pump draws air
4-10 6. Too high a pressure
4-10 7. Valve defective
8. The pump is corroded
8-10-11 9. The pump is worn
10. Impurities in the pump
11. Stuffing box tightened
too much
12. Defects in motor
12. Pipe diameter too small
or pipes clogged up.

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11. SPARE PARTS

11.1 ORDERING SPARE PARTS

When ordering spare parts, please state the following information:

Example

- Serial number 252756

- Item list number (SX-No.) 5310
- Type designation HD81ERM-1U332
- Code of mech. seal, if any AD
- Number of magnetic coupling, if any -
- Number of by-pass valve, if any -
- Item reference of spare part Item CJ
- Designation of spare part Mech. seal

The serial number of the pump, SX No., type designation and code of mechanical seal, number
of magnetic coupling and bypass valve, if any, appear from the nameplate. In addition, the serial
number is stamped on the left hand connecting branch of the pump, seen from the coupling end.
The item reference and designation of the spare part are to be found in the section drawings
(subsection 11.2) and the spare parts list (subsection 11.3).

The example shows the information necessary

for specifying a mechanical seal to be supplied
for a given HD81 pump.

11.2 SECTION DRAWINGS OF SPARE PARTS

The following pages show a representative selection of ROTAN assembly drawings. Not all
pump configurations are represented, but the drawings show all item references and
configurations that generally apply.

23
HD..EDK
(GP..E)
(HD..ECHD)

CHD

GP..EM
(HD..EM)

24
CD/PD..EDKMMW
(CD/PD..EMM)
(CD/PD..EMMP)

MM

MMP

CD/PD..E

25
ED...EDKG

Relief valve for HD, GP (CD, PD, ED).

Relief valve for CD, PD (ED) – 26/33/41

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11.3 LIST OF SPARE PARTS

Item Designation Item Designation

A Pump casing BN Seal housing
B Joint ring/O-ring BP Intermediate bearing
C Joint ring BQ Gasket
D Bolt BR Distance ring
E Bolt BS O-ring
F Bolt BU Rotor
G Pipe plug BV Shaft
J Drive screw BY Ball bearing nut
K Name plate BZ Ball bearing locking ring
S Blind cover CA Key
T Pipe plug CB Key
U Joint ring CC Fixing ring/distance ring
AA Front cover CD Threaded screw
AB Idler CE Snap ring
AC Idler pin CJ Packing rings/mech. seal
AD Idler bearing CK Mech. seal
AE Lub. nipple/Pipe plug CM Lantern ring
AF Joint ring CN V-ring
AJ Heating jacket CQ Bearing bracket
AK Bolt CR Bearing cover
AL Pipe plug CS Bearing cover
AU O-ring CT Bolt
BA Rear cover CU Ball bearing
BB Packing gland/bearing cover CV Stud bolt
BC Main bearing/ball bearing CW Heating jacket
BD Stud bolt/bolt CX Nut
BE Nut CY Flange
BF Washer DA Motor bracket
BG Pipe plug/lub. nipple DB Coupling
BH Bolt/pipe plug DC Threaded screw
BJ Bolt DD Threaded screw
BL Pin EF O-ring

27
Item Designation Item Designation

EG Seal ring MP Bolt

EJ Bolt MQ Bolt
GA Valve MR Lock ring
GB Spring MS Key
GC Adjusting screw MT Seal ring
GD Nut MU Connecting flange
GE Cap MV Main bearing complete
GF Joint ring MW Spacer ring
GG Pressure plate MX Bolt
GH Pressure plate MY Cylinder pin
GJ Valve cover MZ O-ring
GK Valve casing NA O-ring
GM Pipe plug NB Ball bearing
GN Joint ring NC Temp. sensor
GQ Bolt ND Bearing cover
GR Washer NE Shaft
HD Shield NF Cover
HE Bolt NG Disc spring
JL Joint ring NJ Bolt
KX Bolt NK O-ring
KY Bolt NM Set screw
LT Washer NN O-ring
MA O-ring NP O-ring
MB Pipe plug NQ Key
MC O-ring NS Intermediate piece
MD Roll pin NT Threaded fitting
ME Bolt NU O-ring
MF Bolt NZ Draining plug
MG Bolt
MJ Canister
MK Inner magnet
ML Bolt
MM Outer magnet
MN Washer

28