‘ToP-T608- @ Jun. 25, 1987 MYSOM OTL PUMP M8OP Handling Manual~ ee Page No. 6. Routine checks 11 7. Troubles and remedies 12 7-1. Oi pressure does not increase 12 7-2. Leakage from the kechanical seal 13 7-3. Overload of electric nator 14 7-4. Vibration and noise 15 8. Disassembly / assembly 16 8-1. Disasseably of the pump 16 8-2, Assembly of the puap 16 8-3. Disasseably of the reliof valve 17 8-4, Assembly of the relief valve 17 8-6. Procedure of the mechanical seal asseably 18 9. Adjustment of the relief 19 valve (24 through 32) sessment ee HE OR eo,ye Ho. VW 12 12 13 14 15 16 16 16 7 17 18 Introduction ‘The HYCOH of! puzp,a specially designed high quality screw gear purp, has been developed ut of HYCOH's extensive experience in sanufacturing refrigeration screw compressors for many years. The puap incorporates a specially designed rotor profile,a wale rotor with four(4) lobes and a fenale rotor provided with six(6) lobes. ‘The HYCOH oi} pusp, therefore, has the following special characteristics not found on usual ‘gear puaps: Features: 1) Assures higher pumping efficiency {In comparison with usual gear pupps, the HYCOM screw gear pusp assures for higher puaping efficiency, 2) Conpactness and high perfornance ‘The HYCOH oi! puap has Targer displaceaent per rotation than other gear pumps Provided with gear profile of the same size (Dia. x Width) as the screw gear pump rotor. The dimensions of the HYCOM oi! pump are therefore relatively saaller than those of other puaps of equivalent capacity. 3) Wide selection of r.p.m. and displacesent The HYCOM oi! puan offers a wide selection of r.p.m. specs from low to high speed, and punp displacement can easily be selected based on r. p.m. 4) Ho axial thrust means longer 1ife ‘Axial thrust has been coapletely eliminated in the HYCOH oil pump by utili of a double helical rotor profite. This minimizes bearing wear and assures longer |ife of the punp.4) Less noise and vibration during operation 2 6) High sealing efficiency The wechanical seai material has approxinately two tines of the frictional durability of parts made of conented carbide, ‘The wechanical seal of the HYCOH oi! puap is made of silicon carbide to assure long service life,2. Standard specifications 2-4, Standard specifications Design pressure *. 20 (Kot /edt) Viscosity range + 3~500 (cst) Max. temperature > 80 (C) Adjustable range of the relief valve : 1~4 (Kgf/cal) Driving direction 2 Clockwise Suction : Right side Discharge 2 Left side 2-2. Capacity Tho standard capacity of the HYCOH MP series oi! puap is shown in Table 2-1 below: Table 2-1. Capacity and Brake KH of HYCOH HP series oi! puap Total 5OHZ 6OHZ bressure | Displacesent | Brake KW], » , [Displacement [Brake MW] 5 Hodel Ho. | kgt/ad | £ ain, iJ LAin. cd 480P-BPH 3 281 an| 90 at 342 | 1150 480P-4PH 3 ar 4.64 | 1450 516 5.68 | 1750 ~ Note : Figures shown above are based on 100 cst oil viscosity.2-3. Hode! number designation (Standard Hodel) (Add! tional) M8 0P~4PMU-R80HO4 Table 2-2, Hodel_nuaber designation Whether built-in type relief valve is included or tot: 1 :With relief vaive (Standard type) 02 :Without relief valve (Special type) Fluid temperature : ‘S:Max, 80C (Standard type) Hi Hax, 130 (Special type) LiHax.- 40 (Special type) Inside dia. of suction and discharge flanges : Driving direction (Viewed from drive shaft side) R : Clockwise L + Counterclociwise Distinction of features + Ut Purp unit complete with sotor, coup! ing and coupling cover Drive rotor : M:Male rotor drive No. of motor poles : 4P :4 pole aotor GP :6 pole motor Hajor odel No. M8 OP : Pup with 80 me dia, rotor3. Component parts 3-4. Component parts3-2. Table of coaponent-parts et Table 3-1. Component parts of the puap ta PARTS NAME Da, No. [Q'ty | REMARKS 3. [Drive rotor oapiosoo [1 4 | idle rotor - ospia40o [1 5. | Gear casing a oep10s00 [4 6 | Seal cover Care [7 | Blind cover oapio70 | 1 | 8 | Seal retainer oapi0800 [1 9 drive rotor bearing : cgptoa0a | T set |2 pesvset | | &4 Idle rotor bearing ‘oeptoao! | 1 set |2 nes/set [ 14 | Hechanical seal asseably ‘eP11400 [1 set 16 | “O'rings osprte00 | 2 | Jis 6 2401 aise a | Key caniatod | 1 [8 x7 xa0 | 22 | Hexagon socket head bolts espa) | 16 [M2 xa 23. [Hexagon socket head bolts ospizand | 6 [Hexzo "24 | Relief valve body cepzo100 | 25_| body flange Coa 26 | Piston ean2na00 | 27_| Adjusting bolt Co 28 | Spring guide : corzaso | 1 | 29_| Soring ae : agpan600 | 1 31_[tiexagon mit oe ogp20e00 [4 [sis M16, class 3 32 [Hexagon cap ut ‘carz0g00 [1 [JIS H6,class 3 38 [locking pin gerato0 | 1 | oa xe 10 34_[ Gasket _ eerett00 [1 $55 [Orrin eae carei200 | 1 [vis 8 2401 a7 36 [Orin a ospzi300 [1 _| vis 8 2401 Pt4 | 37-1} Hexagon socket head bolts oapat4oo [8 | M2 xt0 Hexagon socket head bolts CT f ananion flanges sraoido [2 | 1S 20K 39 [Companion flange bolts ———'| oeraggoo | 16 |w0 xeo | : 8730400 i 0837200, aaTable 3-2. Component parts of the nechanical seal No.[ —DRH. No. PARTS NAME [HATERIAL| °ty | REHARKS 14| oap11400 ‘Asseably,mechanical seal |Sic+ | 1set CARBO 141 | 811410 Rotating ring Sic/ 1 5U8430 142 | 08P11420-1/2 | ‘O'ring (JIS His 90 ) VITOH 1 | JIS B 2401 35 a For FREON 142 | 08P11420-2/2 | ‘O'ring HBR 1 | JTS B 2401 636 2 For Hi3 43 | 08P11430 Floating ring cargon [1 [ce 144 | 08Pti440-1/2 | ‘O'ring (JIS Hs 90 ) VITON 1 | JIS W 1516 P24 A For FREOH 144 | 08P11440-2/2 | *O' ring BR 1 | JIS W 1516 P24 2 For Ni3 145 | 0811450 Spring sussié_ | 9 146 | o8P11460 Spring retainer sussod [1 aT | ospt1470 Set screw sussig_ [2 148 | 0811480 Back-up ring suszoq [1 149 | 08Pt1490-1/2 | “O'ring (JIS Hs 90 ) VITON 1 | JIS W 1516 Gt a For FREON 149 | 08P11490-2/2 | ‘O"ring BR 1 | JIS W 1516 G4 2 For NaS 150 | 08P11500-1/2 | Spacer ring VITON 1 | For FREON A 150 | O8P11800-2/2 | Spacer ring NBR 4 | For Nis 2 61 | 08P11510 Stopper ring susago [1 152 | ap11520-1/2 | ‘O'ring VATON 1 {JIS W 1516 P21 4 For FREON 162 | 8p11820-2/2 | ‘o'ring NBR 1 [dis 4 1516 P21 for Ni3-3, Sectional view of the puap assexbly LI v € 0GH T9POH JO HOTA [RUO]IDOS “Z- LT cin cin | cin cin4. Special cautions : 4-1. Installation 1) Instat tation point The suction pipe end should be as close to the fluid source as possible and longer than the height of the suction header. The fever accessories on the suction side improve on the suction resistance, 2) Foundation ‘The foundation of the pump should be strong enough to bear sotor driving torque and keep shaft of the pump and the motor aligned. 3) Centering Centering should be carried out after installation is coapleted. Centering adjustuent should comply with the following al lovable specifications: Less than 0.05 am Less than 0.10 am Parallel error Inclination error Regarks : Poor centering adjustment nay cause rapid wear of moving parts, vibration, noise, etc. . 4-2. Care must be taken with piping work 1) Resistance in the suction side piping should be kept to a wininua, Suction strainer: 100 to 200 (mesh) 2) With piping work,care aust be taken to prevent prestressing of piping due to velding Strain. Sharp pipe bending is to be avoided to mininize fluid resistance,3) during piping work,all openings of the puap should be provided with the blind — ~ covers to prevent foreign matter from entering the pump. 0 not forget to reaove blind covers after piping work finished. 5. Operation 5-1. Precautions when starting ' 1) Confirm driving direction of the electric wotor. (Disconnect the motor coupling.) 2) Confira that suction line is arranged for satisfactory drawing of fluid by the pu 3) Fully open both suction and discharge valves of the puap. When the pump is provided with the relief valve, leave the relief valve as is when starting and carry out adjustment after comencing operation, 4) Turn coupling by hand to confira saooth rotation. If coupling rotation is not ‘saooth, the pump should not be started until rubbing is eliminated. 5) then starting operation, first switch on for several seconds to confira norsal operation, then commence operation. 5-2. Caution during operation 1) After continuous operation has been started, check for abnormal pressure, vibration, noise, shaft seal mechanisa, etc. and rewedy if necessary. 5-3. Caution after operation shut down 1) Suction and discharge valves should be closed after the motor is stopped. S-4. Other cautions 1) The puso should be operated strictly in accordance with specifications given. 2) A strong shock to on or forcible packaging of the pusp are to be avoided.6. Routine checks 1) Leakage from the mechanical seal should not exceed Hax.3 cc/hr. 2) Leakage fron casings other than the eechanical seal should be checked for constantly. 3) Check for changes in pressure and flow rate, 4) Mechanical noise should be woni tored, 5) Abnorsal tesperature increases of the component parts should be located as soon as possible.7. Troubles and remedies T-A. Oi1 pressure does not increase Oil pressure does Rot increase Confira driving direction j—-{ Suction valve is |-—-f Open suction valve closed fully [—~[ Bypass circuit is }—J Close bypass circuit onen tightly [7 Preset working pre- | —~] Adjust preset worki ssure on the relief pressure on the valve is too low relief valve Driving direction | is correct ‘Suction pipe end is ‘Adjust suction pine not reached and immersed in fluid Oil viscosity drops |-—={ Cool down oi! texpe- due to oi! teapera- ature ture increase [+ Resistance after the |—> Partially close con- bressure gauge is trol valve on discha- too stall roe tine slowly Driving direction is incorrect Change driving direction Pr7-2. leakage from the wechanical seal Leakage froa the | ~/ Pressure in eechani: Confira preset value }—{ Check that pressure echanical seal cal seal box, is too (pressure) is within specifica high tion Rubber parts have Replace parts with deteriorated, hardened ew ones: | or cracked c Shaft seal surface Dry operation [| Confirm operation of is worn out lubrication circuit for mechanical seal asseab ly Clogging }-7] Check and clean out slurries and dirt ] Hechanical seal faci |—_———___+[Replace nechanical gue seal assenbly with new one7-8. Overtoad of electric motor Overload of elect- ric motor Confira driving direction specifications Discharge pressure |—={ Adjust discharge pre is too high ssure according to Fluid viscosity is |-—=[Should Fluid visco- [too high sity be higher than designed, adjust by iving direc | ‘warning the fluid oor I Turn shaft by hand | —~ Readjust shaft align-] to check went is correct Ly Shaft alignment is Bearing contact is ]—~{ Control tesperature ‘uneven due to tespe- at bearing according rature change to specifications Driving direction Lis incorrect t Change the driving directionVibratory and noisy Driving direction is incorrect Driving direction is correct I Change driving direction | Confira centering al igngent Eo Centering ali- Centering alignsent is |}——~ Adjust al ignnent or gngent is sati oor replace coupling with sfactory nets one From bearing Bearing has worn out Replace bearing with new one Bearing has broken Determine sour--f~{ Vibration or Cavitation |-+>{ suction side |{ Disasseable and clean ce of vibration | | noise origina- strainer is or noise ting from in- clogged side of pump is sucking air Suction side |—={ Confira and adjust Contact is not even due to |—»| Disasseable, check and entry of foreign satter renove foreign matter Vibration or noise ori ginating fron room, foundation or piping vibration or noise in Detersine source of })~{Resedy vibration or nois ining or foundation | '+fAdjust or replace piping Sate8. Dis at. y 2) 3) 4) 5) 8) a 8) assembly/assembly ~ Disassembly of the pump Disconnect the coupling. Resove the puap from the comzon base. Loose the set screw on the coupling. Draw the coupling out of the shaft. Reaove the relief valve from the pump, if there are. Reaove the seal retainer(8) frou the seal cover(6). Rewove the seal cover(6) froa the gear casing(5). Loose the set screw(147) of the rotating ring(141).. Regove the Bechanical seal(14) from the drive rotor(3). Remove the blind cover(7).froa the gear casing(s). Draw the rotors(3 and 4) from the blind cover side of the gear casing(S) “1 If it is difficult, tap the shaft end softly with a plastic aallet. 2 The bearings(9-1 and 9-2) at the blind cover side draw with the rotors(3 and 4). +3 If temperature of bearings exceeds 30°C, do not resove until tesperature drops below 20%. ‘+4 Drive rotor and idle rotor cannot be disasseabled. Draw the bearings(9-1 and 9-2) at the seal cover side from the gear casing(5). 8-2. Assembly of the pump 1) 2) 3 4) Clean the all parts listed in table 3-1,and arrange then on a clean and dry cloth. Fit the Interlocking warks of the drive rotor(3) and the idle rotor(4), and inter- lock the rotors. Insert the rotors(3 and 4) into the blind cover side of the gear casing(5). Coat the all surfaces of bearing with oil. Point the groove of the bearing(9-1 and 9-2) to the discharge side,and mount the bearings to the rotors(3 and 4). 5) 8) 7 Coat the blind cover(7) and the *O"ring(16) with oil. Set the 'O'ring(16) to the blind cover(7). Install the blind cover(7) to the gear casing(5).8) Assenble the sechanical seal assenbly(14), -the seal cover(6) and the seal retainer (8). Refer to details of 8-5, procedure of the mechanical seal assembly. 9) In case the pun has the relief valve(24), install the relief valve to the gear casing(5). If not so, install the blind plate(S0) to the gear casiv:i(5). 8-3. Disasseably of the relief valve Renove the relief valve(24) from the pump. 2 1) Reaove the hexagon cap nut(32). 2) Loose the relief valve adjusting bolt(27) by turning counterclockwise fully, 3) Rewove the hexagon nut(31) 4) Draw the hexagon socket head bolts(37-2). 5) Regove the relief valve flange(25) with the relief valve adjusting bolt(27) and the spring guide(28). 8) Draw the relief valve adjusting bolt(27) with the °O'ring(36) fro the relief valve Flange(25). 7) Renove the spring guide(28) by turning clockwise. 8) Draw the soring(29) and the piston(26) fro the relief valve(24). 8-4, Assembly of the relief valve Arrange the parts listed in No.24 ~37-2 of table 3-1 on a clean and dry cloth. 1) Coat the piston(26) with oi. 2) Insert the piston(26) and the soring(29) to the relief valve(24). 3) Mount the "O'ring(36) to the relief valve adjusting bolt(27). 4) Insert the relief valve adjusting bolt(27) to the relief valve ftange(25). 5) Screw the spring guide(28) to the relief valve adjusting bolt(27). 8) Coat the ‘O° ring(35) with oi, 7) Set the ‘O'ring(35) in the relief vaive flange(2s), 8) Install the relief valve flange(25) to the retief valve(24). * Point the locking pin(33) into the groove of the relief vaive(24) See9) ‘Screw the hexagon cap nut(32). = Install! the relief valve to the punp in exactly direction. For of! pressure adjustwent of the relief valve ,refer to Page 19 ~ 20, 8-5. Procedure of the wechanical seai asseably 1) 2 3) 5) 8) Q 8) 9) 10) 1) Arrange the parts in peaces listed in Fig.8-1 on a clean and dry cloth, Coat the "O'ring(182) with oi. Set the ‘O'ring(182) in the stopper ring(151). Hount the rotating ring(141) to the drive rotor(3). Screw the sot screw(147) on the rotating ring(14t). Coat the "O*ring(144) with oil. Set the "O'ring(144) in the floating ring(143). Mount the floating ring(143) in the spring retainer(146). Insert the spring retainer(145) in the seal cover(6). Coat the ‘O'ring(149) with oil. Hount the ‘O'ring(149) in the seal cover(6), Install the seal retainer(8) to the seal cover(6). Fig.8-1. Sectional view of mechanical seal asseably9. Adjustment of the relief valve (24 through 32) ~ Fig.9-1. Sectional view of the relief valve NAAT Table 9-1. Parts of the relief valve ta] PARTS NAME [ml] PARTS NAME 24 | Relief valve body 28 | Soring guide 25 | Body Flame ~~ 20 Sorina 26 | Piston z 31 [Hexagon nut 27 | Adjusting bolt | 32 | texagon cap mut - 19 -‘9-1. Take off hexagon cap nut(32) and todsen hexagon nut(3t), 9-2. Turn adjusting bolt(27) clockwise to increase oi! pressure and counterclockwise to decrease, Remarks : 1) Pressure increase per rotation of adjusting bolt ts approximately as shown below : Hodel No Pressure increase per turn (K9/ca) +480P 0.25 ~ 0.30 2) Haximua effective rotation of adjusting bolt is 16 turns frow fully open status position turning counterclockwise.