INSTRUCTION AND MAINTENANCE MANUAL

3 SCREW PUMP

PHS MUM – PHS – ENG – 07 – 10 - 0

MUM – PHS – ENG – 07 – 10 page 2 of 21

1 GENERAL INDEX

1  GENERAL INDEX ............................................................................................................. 2 2  PREAMBLE ...................................................................................................................... 3 3  MACHINE DESCRIPTION ................................................................................................. 4 4  TECHNICAL CHARACTERISTICS .................................................................................... 5 5  IDENTIFICATION .............................................................................................................. 6 6  SAFETY ............................................................................................................................ 7 

6.1  Correct use ................................................................................................................. 7 6.2  Individual protection devices........................................................................................ 7 6.3  General prescriptions .................................................................................................. 7 

7  HANDLING AND SHIPPING .............................................................................................. 8 7.1  General conditions ...................................................................................................... 8 7.2  Safety requirements .................................................................................................... 8 

8  INSTALLATION................................................................................................................. 9 9  PRESSURE RELIEF VALVE ADJUSTMENT ................................................................... 10 10  MAINTENANCE .............................................................................................................. 11 

10.1  Ordinary maintenance ............................................................................................... 11 10.2  Extraordinary maintenance ........................................................................................ 11 

11  ASSEMBLY DRAWINGS ................................................................................................. 16 12  TROUBLESHOOTING..................................................................................................... 19 13  DISPOSAL ...................................................................................................................... 20 14  WARRANTY ................................................................................................................... 20 15  ENCLOSURES ............................................................................................................... 21 

MUM – PHS – ENG – 07 – 10 page 3 of 21

2 PREAMBLE

This manual contains instructions for machine use and maintenance. Its contents are to be used by operators trained to take necessary precautions during the complete lifecycle of the machine. The scope of the manual is to supply indications to use the machine safely and to perform ordinary maintenance operations. No extraordinary maintenance operations are mentioned in this manual, as they are considered exclusive competence of a technical assistance technician. The technician must intervene on the machine with respect to the technical characteristics of the project for which the machine has been manufactured.

Reading this manual is indispensable. However, this manual cannot substitute the competence of technical personnel, which must have undergone preliminary and adequate training.

The manual must be kept intact and in good conditions during the complete lifecycle of the ma-chine. After consulting the manual, keep it in safe and protected place. If this documentation is lost or damaged, it is possible to obtain a copy from the manufacturer, in-dicating on the order the production batch code, the machine serial number and year of manufac-ture. This machine has been manufactured conforming to the directives in force in the European com-munity and to the regulations taken in the requirements, as stated in the Declaration of Incorpora-tion released by the Manufacturer and enclosed in the manual.

The information in this manual cannot be released to third parties. Any duplication not authorized in writing by SEIM, partial or complete, obtained by photocopying, duplication or with other sys-tems, even by electronic scanning, violates the copyright conditions and legal action can be taken.

MUM – PHS – ENG – 07 – 10 page 4 of 21

3 MACHINE DESCRIPTION

The PHS pump is a screw pump for hydraulic or lubricating fluids (special heavy fuels), destined for multiple uses, such as auxiliary lubrication or cooling circuits. It is available in three versions (25, 32 and 40).

The pump mainly consists of a cast iron body with inlet and outlet mouths integrated in the upper plate.

Figure 1

1 Pump body 6 Key

2 Rear cover 7 Pump shaft

3 Inlet 8 Motor connection flange

4 Outlet 9 Seal drainage

5 Recirculation valve 10 Manometric outlets

1

3

4

7

6

5 2

8

9

10

MUM – PHS – ENG – 07 – 10 page 5 of 21

4 TECHNICAL CHARACTERISTICS

Maximum delivery flow-rate: 170 l/min (45 USGPM)

Allowable outlet pressure *: 16 bars (232 psi) Allowable inlet pressure: -0,7 ÷ 10 bars (-10 ÷ 145 psi)

Kinematic viscosity: 10 ÷ 400 cSt STD (1,2 ÷ 500 cSt special)

Operating temperature: 0 ÷ 120 °C (32 ÷ 248 °F) Max 140 °C (284 °F)

Drive speed: 1000 ÷ 3600 RPM Average noise level: 60 ÷75 dB(A) at 3600 RPM

Filtration grade: 60 micron max (non-abrasive pollutant) ISO 4406 19/16 – NAS 10

Rotation direction: Clockwise, looking at the pump from the motor side

* Reduced pressure limits are determined by fluid viscosity and by drive speed.

For functional characteristics different from those indicated above, contact the SEIM sales office.

Pump dimensions are contained in the technical data sheet TD – STE – PHS – …

MUM – PHS – ENG – 07 – 10 page 6 of 21

5 IDENTIFICATION

The pump has a nameplate showing the name of the manufacturer, the year and month of produc-tion and the production batch code. Always have available this information when contacting SEIM.

Never change or remove these codes, such action makes the guarantee void.

Next to the codes an arrow shows the correct pump rotation sense.

Respecting the rotation sense is fundamental for pump use; an incorrect rotation sense will jeopardize pump operation.

Manufacturer

Pump code

Serial Nr.

Pump rotation direction

MUM – PHS – ENG – 07 – 10 page 7 of 21

6 SAFETY

6.1 Correct use The pump is destined to operate with hydraulic or lubricating oil, within the temperature, vis-cosity and pressure limits indicated at chap. 4 “TECHNICAL CHARACTERISTICS”.

Using the pump in conditions or with different fluids other than those indicated, unless expressively authorized by SEIM, can cause dangerous situations, for which SEIM cannot be held responsible in any way whatsoever.

6.2 Individual protection devices

During maintenance operations, gloves and protection glasses must be worn.

6.3 General prescriptions − Avoid pump components from coming into contact with wet or humid surfaces. − Avoid unauthorized personnel to enter the working area. − Do not wear loose clothing or accessories which may get entangled in moving parts (ties,

bracelets, etc) − Do not wear large sleeve clothing, laces, belts or bracelets or other accessories, which

may be the cause of danger. Any long hair must be gathered together in a manner to avoid dangerous situations.

MUM – PHS – ENG – 07 – 10 page 8 of 21

7 HANDLING AND SHIPPING

7.1 General conditions The pumps are normally supplied in boxes (Figure 2), separated by pressed cardboard on the inside (to avoid damage during transportation) and finally filled with packaging paper. The box is closed and strapped to a pallet and can be handled using a forklift truck (Figure 3). An adhesive label is attached to the box describing its contents. The dimensions of the packaging depend on the type

of pump ordered.

7.2 Safety requirements − The personnel charged to handle the load must use

protective gloves and must be trained to use lifting devices.

− If the packaging remains outdoors during the ship-ping or storage operations, cover it with a tarpaulin cover (see for example Figure 4).

− All optional features ordered with the pump are packed separately and must be covered.

− Follow the instructions on the packaging before handling and opening it.

− Make sure that the transportation and lifting devices are able to support the weight of the packaging containing the pumps as indicated in the documen-tation provided with the supply.

− Lift the packaging only a few centimetres from the floor to avoid swinging of the load and always posi-tion the forks at the centre of gravity.

− Always move the load slowly during handling opera-tions.

− Always check the point where the forks touch under the pallet to avoid some parts being damaged; if necessary use some polystyrene or soft wood blocks to separate the load from the forks.

− Never place one package containing pumps on the top of another package (Figure 5): the packaging will not bear the weight.

Figure 2

Figure 3

Figure 4

Figure 5

MUM – PHS – ENG – 07 – 10 page 9 of 21

8 INSTALLATION

Use a suitable filtration system to protect the pump from any foreign bodies. Check the filtration grade recommended on the technical reference sheet.

a) Open the packaging, lift the pump, bring it to the installation point and fix it. b) Remove the protection cap from the end of the pump shaft (fig. 6), and

lubricate the shaft with a veil of oil (fig. 7).

c) Key the half-joint to the shaft and lock it by tightening the grub-screw, if present (fig. 8).

d) Remove the protection caps from the inlet and outlet mouths and fill the pump, through both mouths, with the fluid to be pumped (fig. 9).

e) Remove the protection cap from the seal drainage hole (Figure 1, part. 9) and connect it directly to the tank.

f) Wait a few minutes until the oil is distributed inside the pump body and add the fluid to be pumped until the inside of the pump is completely full.

Do not start-up and operate a dry pump.

g) Connect the inlet and outlet piping.

h) Check the direction of rotation of the pump by starting the electric motor and observing the direction of rotation of the motor fan or, if easier, the motor shaft through a hole applied in the housing: the direction of rota-tion must comply with the direction of the arrow placed on the name-plate.

Limit the first start-up to the time necessary to check that the di-rection of rotation corresponds to the direction indicated on the pump nameplate. This prevents partial or total damage to the pump in the case of incorrect rotation.

i) Start-up the motor after checking that all the valves on the line are fully open. At this point, the pump begins to draw fluid and deliver the flow-rate.

If the pump does not draw the fluid, stop the motor within 30 seconds and repeat the start-up operations at intervals of a few seconds. If the problem persists, check sys-tem compliance.

j) Run the pump unloaded for a few minutes to facilitate the evacuation of any air present in the fluid.

6

7

8

9

MUM – PHS – ENG – 07 – 10 page 10 of 21

9 PRESSURE RELIEF VALVE ADJUSTMENT

The maximum pressure valve integrated in the pump is an internal recirculation valve and its func-tion is to limit the maximum pressure in the plant, only during emergencies, faults and bad ma-noeuvres. During normal working conditions the valve is closed.

Normally, the valve is pre-calibrated by SEIM during the pump bench test.

Do not alter or modify valve components.

The pump is available in two versions, respectively with a fixed or variable adjustment. In the case of a variable adjustment valve, the customer can adjust the pressure of initial opening or total re-circulation according to the needs of the plant (in the field of valve adjustment).

The pressure difference (Δp) between the initial opening pressure and the internal total recircula-tion pressure varies according to the pump format, the velocity and viscosity of the fluid being pumped; normally no more than 4 bars.

The adjustment procedure should be started when the valve is in a completely open condition (minimum pressure).

Turning the adjustment screw in an anti-clockwise direction, the valve calibration pressure in-creases.

MUM – PHS – ENG – 07 – 10 page 11 of 21

10 MAINTENANCE

All maintenance interventions must be carried out when the pump is stopped and after disconnecting the motor power supply. Maintenance operations are reserved to trained and competent person-nel. SEIM declines all responsibility for damage to persons or property caused by:

− Interventions performed not in compliance with the indications in this manual;

− Interventions performed by unauthorized personnel; − Use of non-original spare parts.

10.1 Ordinary maintenance Ordinary maintenance requires the following operations, to be performed periodically:

− Clean the pump externally; − Check for leaks; − Tighten the nuts and screws.

10.2 Extraordinary maintenance Disassembly of the mechanical seal

a) Empty the pump and disconnect the piping. b) Disconnect the joint and extract the half-joint.

c) Discharge internal pump pressure: Adjustable valve: loosen, without completely unscrewing, the adjustment nut (fig. 10-A), turn the adjustment grub-screw clockwise up to the locked condition. Fixed or adjustable valve: Unscrew two of the four screws (fig. 10-B), making sure to choose the screws on one of the two diagonals, then substi-tute them with longer bolts. Now loosen the other two screws slowly to discharge the pressure. d) Open the rear cover by completely unscrewing the four

screws (fig. 10-B). e) Place the pump down so that the shaft faces upwards.

f) Remove the Seeger ring using special pliers (fig. 11).

g) Mount the shaft on a clamp (fig. 12) or other device, to be able to lever and extract the central body (fig. 13), and the two side screws.

11

12

13

A B

10

MUM – PHS – ENG – 07 – 10 page 12 of 21

h) Remove the key from its seat on the shaft (fig. 14). i) Remove the Seeger ring used to fix the shaft (fig. 15-A)

and the shim placed on the shaft (fig. 15-B). j) Remove the Seeger ring used to fix the bearing (fig.16).

k) Extract the bearing (fig. 17), using an extractor.

l) Extract the central screw using an extractor or a wooden or plastic mallet giving light strokes on the front part.

m) Slide out the rotating part of the mechanical seal (fig. 18), from the central screw by pulling it and at the same time making it turn in the opposite direction to the winding of the helical spring.

n) Extract the fixed part of the mechanical seal from the seal-carrier bush.

Assembling the mechanical seal

During assembly, the lapped surfaces of the seal must not be placed downwards on the workbench; they must be placed with their tracks facing upwards.

FIXED PART OF THE SEAL: a) Using alcohol, wash well the seat of the fixed part of the seal

on the motor connection flange and the O-ring of the seal fixed section.

b) Wet with alcohol the seal seat and the O-ring, fit the fixed section of the seal into the seat on the motor connection flange, using a soft tool (A = NYLON I PTFE), with a flat sur-face and applying a constant force (fig. 19).

c) Blow with air to evaporate the alcohol.

d) Wipe the contact track with a clean cloth (cellulose, not cotton) soaked in alcohol and let it evaporate. Lubricate the contact track with clean oil.

ROTATING PART OF THE SEAL:

a) Hold the central screw still. Make sure that the central screw is clean and without any cutting edges. If necessary, polish the shaft using fine abrasive cloth (grade 400-1000 approx.), soaked in oil and gasoil, even if it was machine ground.

14

15

A

B

16

18

17

19

MUM – PHS – ENG – 07 – 10 page 13 of 21

23

b) Spread a veil of grease on the seat of the seal on the central screw, including the initial bevel. Using a feeder tool (fig. 22), fit the rotating part of the seal (fig.20), by turning it in the op-posite direction to the winding of the helical spring up to the stop on the circlip and check for good axial running (fig.21).

GREASE MUST NOT BE PRESENT ON THE CONTACT TRACK; to be sure, wipe it with a clean cloth soaked in alcohol and let it evaporate.

c) Lubricate the contact track with a few drops of clean oil, posi-tion the central body on the central screw, follow points “j, i, h” on page 12 in the opposite sequence.

d) Reposition the side screws with respect to the central screw, using the notches as a reference (fig. 23): the notches must be in the position indicated in the figure.

e) Introduce the assembly into the pump body (fig. 24).

f) Place the pump on a flat surface with the shaft in its upward direction and place a hollow metal cylinder on to the screws assembly (fig. 25).

g) Press onto the cylinder using a bear-ing extractor (fig. 26), until the screws assembly reaches the stop of the stroke.

h) Place back the locking Seeger ring (fig. 11), position the flat gasket on the end of the body (fig. 27) and in-sert the key on the central screw (fig. 14).

Make sure that the central screw turns freely.

i) Close the rear cover making sure to correctly insert the pressure relief valve (see later the instructions regarding valve assembly).

24

25

26 27

20

21

22

MUM – PHS – ENG – 07 – 10 page 14 of 21

Pressure relief valve disassembly

a) Remove the ball cup nut on the rear cover. b) Remove the counter nut.

c) Unscrew two of the four screws, making sure to choose the screws on one of the two diagonals, and then substitute them with longer bolts. Now loosen the other two screws.

d) Extract the cover with the obturator guide element and all other parts of the valve (spring, spring guide) and the obturator from the seat on the body.

e) Extract the obturator guide still on the cover and check the O-ring (substitute if neces-sary).

Bearing disassembly

Perform the seal disassembly procedure up to and including point k). Bearing assembly

a) Fit the bearing on the central body and lock it using the Seeger ring (fig. 16). b) Mount the central body with the bearing onto the central screw and bring it to the stop,

add the shims and close using the Seeger ring (fig. 15).

Make sure that the assembly turns freely

c) Perform the mechanical seal assembly instructions.

Pressure relief valve assembly a) Position the obturator into the seat on the body.

b) Position the O-ring in its seat on the obturator guide (threaded pin for an adjustable valve) using Silon Comp 101S grease and insert into its seat on the pump cover (bev-elled hole side).

If it is an adjustable valve, screw in the obturator guide onto the threaded pin and bring it to the stop.

c) Insert the anti-rotation element as indicated in fig. 28, (if the valve is adjustable).

d) Insert the spring (fig. 28), and place the valve back into the body (fig. 29).

e) Position the cover centring the obtutator guide with the hole present on the obturator and lock the four fixing screws in a slow and gradual manner, alternating the screws on one diagonal with the screws on the other diagonal.

28 29

MUM – PHS – ENG – 07 – 10 page 15 of 21

f) Insert the locking nut and counter nut (or the washer and the screw, if the valve is ad-justable).

Disassembly of the radial seal for the shaft

a) Perform the seal disassembly procedure up to point l). b) Extract the stop Seeger of the radial seal for the shaft.

c) Extract the radial seal.

Assembling the radial seal for the shaft a) Apply Silon Comp 101S grease on the internal diameter of the seal and on the exter-

nal diameter of the Gasket Seal. b) With the central screw positioned in the seal holder-ring, and with the help of a feeder,

fit the seal onto the shaft, making sure to position the lip towards the inside, and then bring it to the stop on the seal holder-ring.

c) Lock using a Seeger ring for external diameters.

d) Insert the Seeger ring on the shaft. e) Follow the instructions for bearing assembly.

MUM – PHS – ENG – 07 – 10 page 16 of 21

11 ASSEMBLY DRAWINGS

N DESCRIPTION N DESCRIPTION 1 Pump shaft 19-1 Hexagonal nut 2 Key 20 Ball cap nut 3 Seeger ring 21 Valve guide rod 4 Shim spacer 22 O-ring * 5 Bearing * 23 Valve packing ring 6 Seeger ring 24 Obturator guide rod 7 Screw plug 25 Spring 8 Seeger ring 26 Obturator valve 9 Lip gasket 27 Central screw ring 10 Screw plug 28 Shim spacer 11 Spring 29 Seeger ring 12 Ball 30 Body 13 Cylindrical pin 31 O-ring * 14 Mechanical seal * 32 O-ring * 15 Plug 33 Seeger ring 16 Flat seal * 34 Seal holder-ring 17 Hexagonal socket head screw 35 Anti-rotation element 18 Side screw 36 Cylindrical pin 19 Closing plate

* Spare parts kit

PHS 025

MUM – PHS – ENG – 07 – 10 page 17 of 21

N DESCRIPTION N DESCRIPTION

1 Pump shaft 19 Closing plate

2 Key 20 Hexagonal nut

3 Seeger ring 21 Valve guide rod

4 Shim spacer 22 O-ring *

5 Bearing * 23 Valve packing ring

6 Seeger ring 24 Obturator guide rod

7 Screw plug 25 Spring

8 Seeger ring 26 Obturator valve

9 Radial seal for shaft * 27 Central screw ring

10 Screw plug 28 Seeger ring

11 Spring 29 Shim spacer

12 Ball 30 Body

13 Cylindrical pin 31 O-ring *

14 Mechanical seal * 32 O-ring *

15 Plug 33 Seeger ring

16 Flat seal * 34 Seal holder-ring

17 Hexagonal socket head screw 35 Anti-rotation element

18 Side screw 36 Cylindrical pin

* Spare parts kit

PHS 032

MUM – PHS – ENG – 07 – 10 page 18 of 21

N DESCRIPTION N DESCRIPTION 1 Pump shaft 18 Closing plate

2 Key 19 Hexagonal nut

3 Seeger ring 20 Ball cap nut

4 Shim spacer 21 Valve guide rod

5 Seeger ring 22 O-ring *

6 Bearing * 23 Valve packing ring

7 Seeger ring 24 Anti-rotation element

8 Radial seal for shaft * 25 Obturator guide rod

9 Cylindrical pin 26 Spring

10 Ball 27 Obturator valve

11 Spring 28 Central screw ring

12 Screw plug 29 Seeger ring

13 Mechanical seal * 30 O-ring *

14 Plug 31 O-ring *

15 Flat seal * 32 Seeger ring

16 Hexagonal socket head screw 33 Body

17 Side screw 34 Cylindrical pin

* Spare parts kit

PHS 040

MUM – PHS – ENG – 07 – 10 page 19 of 21

12 TROUBLESHOOTING

PROBLEM SOLUTION

Incorrect rotation direction

Phase connection error For three-phase motors, the two wires used to connect the electrical phases must be inverted

Delivery flow-rate too low

The valves on the line are not fully open Open the valves and restart the pump

The maximum pressure valve value is cali-brated too low

Loosen the adjustment screw until it can be turned manu-ally and start the pump for a few minutes with no pressure. Then tighten the adjustment screw until the calibration value desired is reached.

The filter is clogged or foreign bodies reduce the flow

Check the plant. Check that no foreign bodies are inside the pump.

Pressure too low

Leaks in the piping Check the piping and identify any leaks

The outlet pressure is too low Substitute the pump with a higher delivery flow-rate pump

The maximum pressure valve value is cali-brated too low

Loosen the adjustment screw until it can be turned manu-ally and start the pump for a few minutes with no pressure. Then tighten the adjustment screw until the calibration value desired is reached.

Difficult motor start-up

The pressure required by the system is too high

Check the plant

Oil is too cold Start-up the pump without pressure until the oil returns to its normal temperature. Bring the system back to its working pressure.

The motor is not suitable for the power re-quired

Substitute the motor with a higher power rating motor

The motor calibration relay is too low Increase the relay intervention threshold

The pump is noisy when operating

Check for: No air is present in the system The piping is not too long or the piping section diameter is too small The filter is not clogged or that the inlet valve is not closed The inlet pressure is insufficient The alignment between the motor and the pump is correct The pump is not worn or damaged. Contact the manufac-turer.

MUM – PHS – ENG – 07 – 10 page 20 of 21

13 DISPOSAL

When a pump cannot be repaired or must be demolished, it cannot just be disposed of; it must be sent to a dismantler to be disassembled and to have its materials separated. Most parts of the pump can be easily recycled. When the pump is placed out of service, it is recommended to sepa-rate the materials for reuse or for separated collection for disposal. No materials making up the pump are toxic or dangerous for the health of the operators; therefore, they can be handled with-out any particular precautions.

The disposal of equipment and components at the end of their lifecycle must be carried out by qualified personnel trained about correct handling methods and if necessary for machine disas-sembly.

14 WARRANTY

All SEIM pumps have a 12 month operating warranty and/or 18 months from the date of delivery, unless otherwise agreed in writing. The warranty covers all manufacturing and material defects, and foresees the substitution of spare parts or the repair of defective parts. The material to be re-paired must be sent CARRIAGE FREE.

Once the pump has been repaired, it will be sent CARRIAGE FORWARD to the customer. The warranty does not cover any intervention by SEIM technicians or pump disassembly from the place it is installed. If, for practical reasons, a technician is sent to the premises of the customer, the customer will be charged working costs at current prices, travelling and living costs. THE WARRANTY DOES NOT INCLUDE:

Parts subject to wear; Faults caused by bad use; Faults caused by external agents; Faults caused by negligence or lack of maintenance.

WARRANTY FORFEITURE:

In case of arrears or other breaches of contract; Any repairs or modifications made to the pumps without written consent by SEIM,; Tampering with or cancellation of the pump Serial Number; When damage is caused by improper use and other causes not due to normal working con-

ditions; If the pumps are disassembled, tampered with or repaired by personnel not authorized by

SEIM; In the case that the pumps are used for different purposes other than the purposes de-

scribed in this manual.

Repairs performed under warranty do not interrupt the warranty duration.

MUM – PHS – ENG – 07 – 10 page 21 of 21

15 ENCLOSURES

The following documentation is enclosed with this manual:

− PHS data sheet − Declaration of Incorporation (according to the 2006/42/EC Directive) Any documentation not supplied is intended as being part of Pertinent Technical Documentation in the archives of the Manufacturer.