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INDEX
Chapter
Page No.
Introduction
Performance Characteristics
Operation
Shaft Sealing
16
Installation
17
23
Trouble Shooting
24
Parts List
26
27
10
Dimension Drawing
35
11
36
Introduction
1.1 General
This instruction manual contains necessary information on the AERN series pumps
having pump model of AERX, AERN & AERB and must be read carefully before
installation, service and maintenance. The manual must be kept easily accessible to the
operator.
Important
The pump must not be used for other purposes than recommended and quoted for
without consulting the company or your local distributor.
Liquids not suitable for the pump can cause damages to the pump unit, with a risk of
personal injury.
1.2 Reception, handling and storage
1.2.1 Reception
Remove all packing materials immediately after delivery. Check the consignment for
damage Immediately on arrival and make sure that the name plate/type designation is in
accordance with the Packing slip and your order.
In case of damage and/or missing parts, report immediately to the carrier at once. Notify
your supplier.
Introduction
1.2.2 Handling
Check the weight of the pump unit. All parts weighing more than 20 kg must be lifted using lifting
slings and suitable lifting devices, e.g. overhead
crane or industrial truck. See section 10 Weights.
Introduction
1.2.3 Storage
Storage location free from, dust, moist and vibration free place.
Rotate the pump unit by hand weekly, to prevent jamming and damaged.
1.3 Safety
The pump must not be used for other purposes than recommended and
quoted for without consulting the company or your local distributor.
Always wear suitable safety clothing when handling the pump.
Anchor the pump properly before start-up to avoid personal injury and/or
damage to the pump unit.
Check to see that the pump can be drained without injuring anyone
and without contaminating the environment or nearby equipment.
3
Introduction
Make sure that all movable parts are properly covered to avoid personal
injury.
All electrical installation work must be carried out by electric personnel.
Improper installation can cause fatal injuries.
Dust, liquids and gases that can cause overheating, short circuits, corrosion
damage and fire must be kept away from motors and other exposed equipment.
If the pump handles liquids hazardous for person or environment, some sort of
container must be installed into which leakage can be led. All (possible) leakage
should be collected to avoid contamination of the environment.
If the surface temperature of the system or parts of the system exceeds 60C,
these areas must be marked with warning text reading "Hot surface" to avoid
burns.
Performance Characteristics
2 Performance Characteristics
2.1 capacity
Its calculation helps to find out the suction lift of the pump, which enables to
varify whether the pump will be able to self prime or not.
The suction pressure or termed as NPSH ( Net Positive Suction Head ) can be
calculated by following equation
NPSH = Atmospheric pressure + Static Head - Static Lift
ATMOSPHERIC
PRESSURE
STATIC LIFT
STATIC HEAD
Performance Characteristics
The discharge pressure shown in the delivery line is nothing but the overcoming
of system pressure created by the resistance of the pipeline and the shearing force
of the liquid. Thus it can be said that a gear pump does not develop pressure by its
own but work against the system pressure exerted on it.
2.4 Power Consumption:
1.
2.
3.
4.
The power consumption of a rotary gear pump is mainly influenced by the differential pressure exerted on it.
Factors effecting on power consumption as follows:
liquid viscosity
Sp. gravity of liquid.
Frictional loss.
operating temperature
Performance Characteristics
CAPACITY
THEORITICAL
500 S
SU
200
SS
U
CAPACITY
ACTUAL
IC
SS
20
50
EO
TH
SS
IT
SPEED
HYDRAULIC HP +
VOLUMETRIC LOSSES
FRICTIONAL LOSSES
+
MECHANICAL LOSSES
POWER CONSUPTION
AN NO LOAD
=
OEFFERNTIAL PRESSURE
ACTUAL
20
SS
SS
50
THEORITICAL
SPEED
VOLUME TRIC
LOSSES
ACTUAL
OEFFERNTIAL PRESSURE
POWER CONSUPTION
The change in viscosity very much affects the performance characteristics of the pump i.e. capacity, power
consumption and speed.
POWER CONSUPTION
Operation
3.1 Genral
Gears
Pump Casing
Wear Plate
Seal
Drive Shaft
Bearing
R.V. Cover
Front Cover
Relief Valve
Operation
Suction
Discharge
Suction
Discharge
Suction
Discharge
2.
3.
Operation
This safety relief valve limits the differential pressure (p) between suction and
discharge, not the maximum pressure within the installation.
For example, as media cannot escape when the discharge side of the pump is
obstructed, an over-pressure may cause severe damage to the pump.
The safety relief valve provides an escape path, rerouting the media back to the
suction side when reaching a specified pressure level.
The safety relief valve protects the pump against over-pressure only in one flow
direction.
The safety relief valve will not provide protection against over-pressure when
the pump rotates in the opposite direction.
10
Operation
An open safety relief valve indicates that the installation is not functioning
properly.
When the safety relief valve is not installed on the pump, other protections
against overpressure have to be provided.
If the pump rotates in the opposite direction, the safety relief valve or top
cover must be disassembled and turned around by 180.
Suction
Suction
Discharge
Clockwise Direction
Discharge
11
Operation
To adjust the Safety Relief valve for operating pressure, proceed as follows :
1.
Open the hex cap.
2.
Tighten the ad. screw for increase
set operating pressure or loose the
ad. Screw for reduce the pump operating
pressure.
while increase of operating pressure, power
consumption of pump must not exceed
the motor rated power.
3. Tighten the hex cap. Make sure that air
must leakge from hex cap & ad, screw.
12
Operation
There may be residual mineral oil inside the pump deriving from the pump
testing and the initially lubricating of the bearing bushes.
If the lubricating oil is not acceptable for the pumped liquid, the pump
should be cleaned thoroughly.
13
Operation
3.4.3 Characteristics
The characteristics of the pump unit and safety relief valve to be checked.
Pump model see name plate, RPM, working pressure, effective power,
working temperature, direction of rotation, NPSHr etc. as per application
14
Operation
All guards and safety devices (coupling, rotating parts, excessive temperature)
are placed.
15
Shaft Sealing
4. Shaft Seals:
Mech. Seal
4
spring
O"Ring
1
1
Stationary Face
Rotary Face
L-Ring
1
1
16
Installation
5. Installation:
5.1 General:
Pump performance is also dependence on pump installation. This manual gives
basic information which is to be observed during installation of the pump. It is
important to read this manual by responsible person before installation.
5.2 Location & Foundation:
Locate the pump/pump unit as close as possible to the liquid source and if
possible below the liquid supply level. The better the suction conditions, the
better the performance of the pump.
The pump should always be located where it is accessible for inspection, maintenance and repairing.
Every pump should be provide a good foundation by any strong structure to hold
the pump rigid and to absorb any strain or shock that may be encountered. If a
separate foundation is provided, make it at least 4 wider and longer than base
frame.
When the unit is placed on the foundation, it should be leveled and checked
for position against the piping layout and then fastened Owen.
17
Installation
0.200mm
5.3 Alignment:
For running the pump, it is required to couple pump with the drive unit to
The coupling may be direct drive or belt drive. However direct drive is
preferred over belt drive to reduce load on pump drive shaft and bearings.
Pump and drive unit alignment must not more than as shown in fig.
Parralel alignment
18
Installation
5.4 Piping:
Use piping with an equal diameter than the con
nection ports of the pump and shortest possible.
19
Suction
Strainer
Pump
Isolation valve
Installation
level, the inclining pipe should rise upwards towards the pump
without any air pockets.
20
Installation
These valves must have a cylindrical passage of the same diameter of the piping.
When operating the pump, the valves must be opened completely. The
output must never be regulated by means of closing valves in suction or
discharge pipes.It must be regulated by changing shaft speed or by re-routing the
media over a by-pass back to the supply tank.
5.4.3 Strainer
Foreign particles can seriously damage the pump. Avoid the entry of these
particles by installing a strainer.
When selecting the strainer attention should be given to the size of the openings
so that pressure losses are minimized. The cross-sectional area of the strainer
must be three times that of the suction pipe.
Install the strainer in such a way that maintenance and cleaning are possible.
Make sure that the pressure drop in the strainer is calculated with the right
viscosity. Heat the strainer if necessary to reduce viscosity and pressure drop.
21
Installation
Input voltage & frequency must be match with operating drive motor.
22
23
Trouble Shooting
Problem
No flow
Under capacity
Irregular discharge
Low discharge pressure
Pump will not prime
Prime lost after starting
Pump stalls when starting
Pump overheats
Motor overheats
Excessive power absorbed
Noise and vibration
Pump element wear
Seizure
Mechanical seal leakage
Packed gland leakage
Probable Causes
Solutions
Reverse motor.
Gland over-tightened
Gland under-tightened
Pump speed above rated figure.
Pump speed below rated figure.
Faulty motor.
Pumping element missing
24
25
27
28
25
26 2
4
23
22
21
20
19
14
13
11
12
10
15
29
9
16
17
18
8
PARTS
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
DESCRIPTIONS
Parts List
AERN AERX AERB PARTS
PUMP PUMP PUMP NO.
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
DESCRIPTIONS
Stator shaft
Rotor shaft
Bearing Sleeve
Snap Ring
Washer, Gear Shaft Assembly
Bolt, Gear Shaft assembly
Pump Casing
R. V. Cover
Hex Cap, Relief Valve
Adjustment screw
R. V. Plug
Spring Sheet
R. V. Spring
R. V. Piston
Front Cover
9.1 General
Insufficient or wrong assembly and disassembly can lead to the pump malfunctioning, high repair costs and long-term inoperability.
Disassembly and assembly may only be carried out by trained personnel. Such
personnel should be familiar with the pump and follow the instructions below.
ANI Engineers is not liable for accidents and damage of the pump or pump unit
for faulty assembly.
Remove the pump from the operation.
27
28
Remove spring
Remove piston.
23
29
PRESS
SUPPORT
30
32
bearing if damaged)
34
Dimension Drawing
10
Model
OVERALL
DIMENTIONS
H2
A
F
MOUNTING DIMENSIONS
B
H1
FLANGE DIMENSIONS
SHAFT DIMENSIONS
L1
Weight
Kg.
AE-050-S-M-L 239
150
110
80
100
91
80
69.0
12
08
89
16
60
22
30
11.5
13.0
8.0
AE-100-S-M-L 271
160
130
90
110
100
90
74.0
12
10
108
16
79
25
30
15.0
17.0
14.0
AE-150-S-M-L 318
180
145
105
130
119
100
80.0
14
10
127
16
98
25
40
21.0
23.5
22.5
AE-200-S-L
359
200
165
110
150
133
112
89.5
14
12
152
19
121
40
50
24.0
27.0
28.0
AE-250-S-L
419
220
190
130
160
163
132
100.0
15
15
178
19
140
40
55
27.0
30.0
43.0
AE-300-S-L
461
240
220
160
220
166
160
131.0
20
18
190
19
152
53
60
32.0
10
35.0
59.0
AE-400-S-L
554
280
255
180
270
189
180
145.0
22
18
229
19
190
53
65
37.0
10
40.0
82.0
AE-500-S-L
615
295
280
200
300
215
200
160.0
25
19
254
22
216
60
85
47.0
14
50.5
150.0
AE-600-S-L
690
340
318
220
350
215
225
178.0
26
20
279
22
241
70
95
52.0
16
58.0
175.0
AE-601-S-L
749
360
357
240
380
230
250
200.0
28
22
279
22
241
70
100
57.0
16
61.0
190.0
A
L1
L
H2
H1
D 2
4 Nos D1 Holes
B
35
11
36