HYDRAULIC PUMP HY 35 A/B -------------------------------------------Instructions handbook / Spare parts
Via Pasubio, 40 – 40 – 37069 37069 Villafranca (VR) – (VR) – Tel. Tel. +39 045/6304521 – 045/6304521 – Fax Fax +39 045/6335758
[email protected] –
[email protected] – www.dragflow.it www.dragflow.it
HYDRAULIC PUMP HY 35 A/B INSTRUCTIONS HANDBOOK _____________ _______ ___________ __________ _______ __ ____________________ ___________ ____________________ _______________________ _______________________ ______________________ ______________ ___
Ed. 12/11____ Ed.
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INDEX
PRESENTATION..………………………………………………………………. pg. 2 WARRANTY REGULATIONS.…………………………………………………. pg. 3
1.0
DESCRIPTION…………………………………………………………………... pg. 4
2.0
TRANSPORT, ASSEMBLY AND DEMOLITION.……………………………. pg. 5
3.0
STARTING AND OPERATION…………..…..………………………………... pg. 8
4.0
MAINTENANCE AND CLEANING.…..………………………………………... pg. 9
5.0
pg. g. 12 NOISE…..…….…………………………………………………………………... p pg. g. 13 HYDRAULIC CONNECTIONS……..…………………………………………... p
6.0
SAFETY…………………………………………………………………………... pg. 15
pg. g. 16 SPARE PARTS……..……………………………………………………………. p WEAR SPARES……………...………………………………………….………. pg. 21
7.0
TECHNICAL SPECIFICATIONS…..…………………………………………... pg. 22
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PRESENTATION This instructions manual has been conceived and structured for rapid and easy consultation, thanks to the index ordered by subjects, and explanatory figures and tables.
GENERAL WARNINGS This instructions manual must be studied by the owner of the machine, the technical personnel within the factory, the operators, that is, all those that will be using the machine, the maintenance maintenance technician. The manual is an integral part of the machine and contains information on its use, technical characteristics, characteristics, as well as instructions for handling, installation, assembling, assembling, regulation and maintenance. It also contains a section for trouble-shooting, trouble-shooting, if necessary, and for the ordering ordering of spares. The DRA DRAGFLOW GFLOW S.r.l. technicians are always available, by telephone, fax or e-mail, to supply all the explanations that may be needed. This manual: - must be considered considered as integral part of of the machine machine until it is taken to the breakdown breakdown yard; - must be kept in an easily easily accessible accessible place and and suitable suitable for its preservation; - must be consulted consulted each time that that there are problems problems or doubts doubts on the operation operation of the machine; - must be carefully carefully followed followed for whatever regards regards the the necessary necessary maintenance maintenance operations set out out in it.
In case it is lost, apply for a copy directly from DRAGFLOW S.r.l. DRAGFLOW S.r.l. reserves the right to carry out all modifications to update the machine or instructions manual according to the technological progress and the state of the art. This constitutes no obligation to carry out modifications modifications to the machines that have already been sold. If the machine is ceded to a third party, it is recommended recommended that of the instructions manual follow it.
DRAGFLOW S.R.L. RETAINS ITSELF FREE FROM LIABILITY OF ANY KIND, KIND, AND ESPECIALLY FOR: improper use of the machine; - - use of the machine by personnel personnel not trained to used it;
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power supply defects; maintenanc maintenance e defects; unauthorized and unforeseen modifications; use of spares spares that that are are not original original or not not specific specific for the model; non observance of the instructions;
The uses of the machine for different purposes are to be considered considered dangerous for the operator and for the machine. Likewise, modalities of installation and utilizations different from that indicated in the present manual could cause damage to persons and/or to the machine itself.
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WARRANTY REGULATIONS DRAGFLOW S.r.l. guarantees the original user that the machine will be reasonably free ffrom rom factory and material defects. This warranty lasts for 1 ( one ) year from the invoice date, excluding wear parts ( indicated in section 4.0 of this manual “MAINTENANCE AND CLEANING” ), and refers to the connection of any defect that will be recognized by DRAGFLOW S.r.l. as being subject to warranty (after presentation of adequate proof of claim), in one of the following ways and at the discretion of DRA DRAGFLOW GFLOW S.r.l.: S. r.l.: - replacement of defective defective part with a new one, made made available available in the offices of the Purchaser at the the lowest transport rate; repair of defective part, after this has been returned to DRA DRAGFLOW GFLOW S. S.r.l. r.l. with transport expenses - prepaid.
As soon as the spare spare is ready, The C Client lient will make make the defective part available available to DRAGFLOW S.r.l. The warranty does not apply to those parts that result defective defective because of incorrect use, handling or bad observance of the use and maintenance instructions supplied by DRAGFLOW S.r.l. The consumable parts or those parts subject to normal wear ( such as seals and gaskets, impellers, impellers, stirrer, wear-plates, volutes and electrical components components ) are not included in this warranty. If the Purchaser tries, either to repair any fault that is under guarantee, or obtain direct supply of the spare part without previous written consent of DRAGFLOW S.r.l. the latter will not be responsible for the results of the repair and will not be held to reimburse the expenses sustained by the Purchaser. DRAGFLOW S.rl. declines all responsability for the expenses due to “down time”, business costs and losses deriving there from. All justifiable claims claims of breakdown breakdown will be be transmitted in writing writing by the Purchaser Purchaser to DRAGFLOW S.r.l. before expiry of the warranty. There are no other guarantees, explicit explicit or implicit, that can be treated or adapted for any particular purpose.
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1.0 DESCRIPTION STRUCTURAL STRUCTURA L DESCRIPTION OF THE MACHINE (Fig. 1)
The Dragflow hydraulic pumps are made of high quality materials and undergo severe controls before leaving the factory. They are essentially composed of a cover 1, on which the hydraulic motor 2 is fitted. Inside the oil housing 3 is housed the group of seals 4 preventing the water from passing to the motor. On the main shaft 10, inside the casing 5, there is a keyed impeller 6, made in high chrome content anti-wear materials. A wear plate 7, made with the same material, partially closes the impeller inlet. Inside the strainer protection 8 houses a cutter 9 that rotates and stirs the mixture of solids in the water to be pumped.
Fig. 1
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2.0 TRANSPORT, ASSEMBLY AND DEMOLITION Dragflow pumps are generally generally transported encased encased inside a crate to avoid damage to the pump or parts of it. The crate is arranged for unloading with a fork-lift truck, whose capacity must be able to sustain the weight of the pump ( see data sheet enclosed in this instructions handbook ) as shown in Fig. 2. The pump is placed inside the crate as seen in Fig. 3, it must be freed from the packing and lifted with ropes hooked to the appropriate lifting plate A.
Fig. 2
Fig. 3
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INSTALLATION 1) Connect the delivery pipe. - The delivery pipes must never form siphons (Fig. 5) to avoid problems due to the formation of air
pockets or deposits of solid material.
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Before connecting then pump to the hydraulic supply source, make sure that all the data on the rating plate correspond ( max. pressure, etc. )
Fig. 4
Fig. 5
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Connect the oil supply pipes to the pump as indicated in Fig. 6. DISMANTLING
Before doing anything on the pump, be sure to disconnect the hydraulic supply and the delivery pipes. Warning: the machine that is considered completely completely useless must be removed from the d department epartment and collected by the manufacturer or any other firm f irm specialized in demolition. Remember that dismantling the machine in your establishment will “produce” different materials materials ( metals, plastics, oil, etc. ) whose disposal disposal will be done in compliance with the legislative regulations in force in the state where the machine is found.
(DELIVERY) PIPE ¾” ¾” - 250 bar
(RETURN) PIPE 1” 1” - 100 bar
(DRAINAGE) PIPE ½” return free at the tank
Fig. 6
The drainage oil must be collected in non-pressurized non-pressurized tanks. “Free return” means that there must be nothing that impedes the drainage ( narrowing, valves, valves, filters, etc. )
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3.0 STARTING AND OPERATION STARTING
The pump has been created to pump suspended matter, even with solid parts, as long as water is always present. It can be used for civil and industrial purposes, purposes, as long as conditions described in this manual are observed. Check the direction of rotation: by passing very short impulses and check that the direction of rotation is that indicated on the rating plate. 1) Immerse the pump in clear water. 2) If any priming problems should come up, stop and wait for about 30 seconds, leaving it immersed, until all the air has been eliminated. 3) Check that: when pumping only water H2O, the operating pressure always stays at least 20 - 30% below the set maximum pressure. 4) Slowly lower the pump until it comes into contact with the material. 5) Check the percentage of solid to avoid exceeding the maximum pressure threshold. 6) When clean water is not available, but only mud and other mixtures, mixtures, check that the pump does not go over the maximum pressure indicated indicated on the rating plate (Fig. 7); however, if this does happen, create a further load loss, bypipes; doing what is set out below: - by adding - by creating bottlenecks; bottlenecks; - raising the discharge height; 7) Before stopping the pump, it is always a good rule to pump water with very little solid in it, so that t hat the pipes are washed.
EMERGENCY EMERGENC Y SITUATIONS
The correct use of the machine excludes the possibility of emergencies happening during operation or during cleaning and maintenance, unless the latter have not been b een done in compliance with this instructions manual. If there is any imminent mechanical danger, danger, stop, or have the pump stopped by disconnecting it from the hydraulic supply. An accurate search search for the fault, or anomaly that caused the danger, must be carried out soon afterwards, and once detected, see to resetting the operation of the machine and of the protection p rotection set-up. If necessary, have DRA DRAGFLOW GFLOW S.r.l. Service or competent personnel from another firm carry out any repairs or work.
MAXIMUM PRESSURE
Fig. 7
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4.0 MAINTENANCE AND CLEANING Warning: maintenance and cleaning of the machine must be done after having stopped the machine. 1) Check the tightness of the fastening screws every 50 hours of pump operation. 2) Remove the 2 (two) plugs marked by the labels GREASE, Fig. 8, and restore the grease with 50 grams of it for each greaser, using a hand grease gun. Seals zone must be greased every 8 hours. 3) Every 200 hours check the clearance between the impeller 47 and the lower wear plate 46 is as follows (see Fig. 9). - keep the pump in a vertical position; dismantle the strainer 42 by removing the screws in position 52; - - check that the clearance is not more than 1 mm, if it is wider proceed as follows: - slacken of the fastening fasten ing screws 7; - take the wear plate 46 at a distance of about 1 mm from the impeller 47, by turning the adjustment screws 72 and locknuts 73; - check that it rotates freely; - fasten both the locknuts 73, the adjustment ad justment screws screws 72 and the fastening fa stening screws 7 , ( tighten to about +/- 40N ). 4) For customers that work with particularly abrasi abrasive ve materials having a very ffine ine particle size, we advise passing a jet of water under pressure, connecting connecting it to t o tthe he prepared threaded connector connector indicated with H2O (Fig. 8). The pressure must be greater than that exerted by the pump to have continuous cleaning of the area of the seals and so less wear. It is compulsory to grease the area of the seals at the end of each shift or every 8 working hours, use grease such as POLIMER 400 with LIQUILON.
Fig. 8 “GREASE”
-greasing every 150 hours“GREASE” (red plug) -greasing every 8 hours-
“WATER” water washing
impeller
Fig. 9
wear plate
Adjusting screws
Blocking screws ______________________ ___________ ______________________ ______________________ _______________________ _______________________ ______________________ ______________ ___
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5) Check the level and the deterioratio deterioration n of the oil every
Fig. 10
8 hours of operation by removing the plug labelled “OIL” (Fig. 10). For a total oil change or topping up, the following steps have to be taken: a) It good goremaining od practiceoil. to The empty the pump pumplubricant completely completel y ofisthe exhausted must be disposed of in conformity with the laws in force in the country where the machine is used, since its dispersal in the ground will pollute the water beds. beds . This is not necessary if the oil is simply topped up. b) The pump must be be placed in a horizontal horizontal position, position, keeping the plug marked “OIL” pointi ng up (Fig. 11). c) Remove the plug marked ”OIL”. d) Top up until completely completely full or completely completely change the oil with about 5 Kg of oil having the characteristics characteristics as in the table following. following.
Oil type ISO
EP320
320
Density at 15/4 °C 0,900
Cst 40°C
330
Viscosity Cst 100°C 25,8
“OIL” topping up with 5 Kg
E 50°C
24,0
I.V.
95
Flash point
Pour point °C
V.A. °C 240
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e) Before closing the plug change the the copper washer to prevent leaks and water seeping in. If the oil is “milky” white color the seals must be replaced.
“OIL” oil filling Top up in a horizontal position
Fig. 11
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REPLACING REPLACIN G THE SEALS
- -
-
-
-
-
-
-
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Completely empty the oil from the oil chamber. Remove the filter 42 (Fig. 12) by unscrewing the screws 52. 40 byinhitting Unscrew the cutter it ;smartly in anthe anticlockwise direction as shown Fig. 13 make sure impeller 47 (Fig. 12) is blocked with an iron rod. Remove the connection 43 (Fig. 12a), then the nut 39 and the spacer 45. Extract the flange on the suction side 34 (Fig. 12) after having removed the screws 7. With the flange pos. 34 the lower wear plate 46 also will come down. Remove the casing 37 (Fig. 12) after having removed the screws 7. Extract the impeller 47 using two levers “A” (Fig. 12). If it sticks use an extractor, taking care not to damage the threaded part of the motor shaft. Remove the key 38 (Fig. 12) and immediately after the spacer 6 (Fig. 14). To remove the upper wear plate 48
unscrew the screws 7a. Remove the seals housing 56 and 57 after having removed the screws 54 with the ring 55. Replace the seals 53 (n° 1), 49 (n° 3) and 51 (n° 2), the shaft sleeve 24 and the o-rings “OR” 23, 25 and 28 as shown in Fig. 14 taking care not to damage any spare parts.
Fig. 12a
Fig. 12
Fig. 13
40 N.B. First block the impeller 47. Fig. 14 ______________________ ___________ ______________________ ______________________ _______________________ _______________________ ______________________ ______________ ___
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To reassemble follow the instructions instruct ions in the reverse order keeping keeping the pump in vertical position. Remember to adjust the lower wear plate 46 (Fig. 9 pag. 9) as indicated in paragraph 3), before closing the pump definitely. Top up with new oil, according to the instructions of paragraph 5) pag. 10 .
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Periodically, Periodically , check the state of the are hydraulic system ( pipes, pipe fittings, etc.with ). characteristics If parts of the hydraulic equipment to be replaced, only use components that are equal, or at least similar, to those of the original components.
PUTTING THE MACHINE MACHINE OUT OF SERVICE
If for any reason whatsoever the machine should be temporarily placed out of service, it is important to disconnect the hydraulic supply source, clean the fittings of pump and hydraulic motor and cover them to protect them from dust. To put it back into service again again follow the instructions for starting up.
5.0 NOISE The machine was designed and manufactured while at the same time keeping in due consideration air noise hazards. The construction techniques used allow to limit the noise level within tolerable limits in compliance with the Machine Directives 89/392, point 1.7.4.f: - The pondered equivalent equivalent continuous continuous acoustic pressure level is 62 dBA. - The maximum pondered instantaneous acoustic pressure “C” is never above 63 Pa ( 130dB compared to 20mPa ). Air noise detection detection was effected by placing the probe probe two meters from the machine, machine, along the whole whole perimeter perimeter and at a meter from the floor. f loor. The noise was measured under vacuum. This because the machine itself does not require any specific position wat er and therefore the values areoperation non-influencing. non-influencing . fixed by the operator since it is normally immersed in water The observations were done with a model HD9020K1 DELTA OHM PRECISION INTEGRATOR NOISE METER in conformity with the: IEC651 class 1 standard IEC804 class 1 IEC225 filters 1/3 octave The instrument was calibrated with a DELTA OHM HH9101 calibrator conformi conforming ng to the t he IEC942-1988 class 1.
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HYDRAULIC CONNECTIONS
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The DR DRAGFLOW AGFLOW pumps pumps are only supplied supplied with with piston hydraulic hydraulic motors, motors, suitable suitable for circuits where the continuous operating pressure may reach 250 bar. These pressures can only be reached in the worst conditions. Make sure that in the hydraulic power unit, the safety valve is set from f rom 210 up to 250 bar according to the model. TheDragflow drainagepump pipe from the motor must be connected directly to the tank without filters or any other restriction in between.
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Start the pump out of the liquid liquid to be pumped pumped and check the direction of rotation and the speed with a revolution counter. The speed must be adapted to the working conditions ( between 1000 – 1200 rpm, the length of the pipes, vertical height above the water, etc. ), since good operation and the best duration of the pump are obtained by working in the flow rate/head range corresponding to the model concerned ( see the pump curve enclosed in this instructions handbook ).
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6.0 SAFETY Introduction Dragflow s.r.l. has designed and built the machine keeping in mind the results of a preventive and accurate analysis of the risks connected to the use of the machine. The protections and devices applied, therefore, represent the profuse commitment by the Dragflow S.r.l. technicians to achieve the aim of safety sanctioned by the specific directives issued issued by the EEC. The protections and devices are illustrated illustrated below with drawings. Other instructions and information on the safety of the machine are contained in the paragraphs which deal with the use, maintenance maintenance and repair.
All the organs in movement are are segregated segregated inside the pump pump structure. The only rotating mechanical part is the agitator 40 ( Fig. 16 ), that for functional reasons cannot be protected in any way. In fact its specific function is that of cleaning the strainer 42 and stirring the solid bodies present in order to set them in suspension in the liquid to be pumped ( Fig. 16 ). On the pump there is a warning warning plate ( Fig. 15 ) to remind us of this danger.
When about to operate the pump, keep clear of this rotating part in order to avoid accidents.
The strainer 42 ( Fig. 16 ) is made according to the suction capacity of the pump, and does not allow the passage of particles of over 35 mm diameter . It is a good rule not to come close to the pump when it is immersed in water to avoid dangerous situations.
Do not open without having first releasing the hydraulic pressure.
On the pump there is a warning warning plate to remind us of this danger ( Fig. 15 ). The driving hydraulic motor is fed oil under pressure, therefore keep to the safety rules in the table. table.
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Fig. 16
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S P A R E P A R T S HY 35 A A//B
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POS.
Q.
PART NUMBER
DESCRIPTION
6 7 8 13 15 16 17 18 19 20 21 22 23 24 25
1 22 30 1 1 1 1 1 1 1 1 1 1 1 1
F42939 A2501067 A2527005 A1501129 F20622 A1001097 A1001098 F20636 A1003010 A6503044 A1501098 A6503044 A1501108 F42936-1 A1501096
WEARING SPACER SCREW SEAL WASHER O-RING OIL CHAMBER BALL BEARING BALL BEARING SPACER THRUST BEARING SEAL O-RING SEAL O-RING LOWER SHAFT SLEEVE O-RING
26 28 29 30 31 32 33 34 35 36 37 38 39 40
1 1 6 2 4 4 1 1 6 1 1 1 1 1
F23171 A1501097 A2501006 A6502018 A6504064 A1504023 F20637 F20626 A2501022 A6503005 F20616 A2518023 F20632 F20620
GREASE SPACER O-RING SCREW GREASE NIPPLE PLUG WASHER BEARINGS FLANGE SUCTION COVER SCREW UPPER SHAFT SLEEVE CASING KEY AGITATOR NUT AGITATOR
41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 1 1 2 1 1 1 1 3 1 2 12 1 6
A2501027 G20634 F20633/1 A1501130 F20631 F20619 F20617 F20618 A1502114 F24854/G A6503011 A2501020 A6503048 A2501003
AGITATOR SCREW STRAINER STAND AGITATOR CONNECTIVE CONNECTIVE O-RING AGITATOR AGITAT OR SPACER LOWER WEAR PLATE IMPELLER IMPELLE R UPPER WEAR PLATE SEAL DISCHARGE ADAPTER Ø150 SEAL SCREW SEAL SCREW
55 56 57 58 61
6 1 1 1 1
A2527018 F42938 F42937 A1002085 A1001086
SEAL WASHER LOWER SEALS FLANGE SEALS HOUSING ROLLER BEARING BALL BEARING
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POS.
Q.
PART NUMBER
DESCRIPTION
71
8
A2510004
WASHER
72 73 75 78 80 81 82 83 84 85 86 87
16 16 2 2 1 4 4 1 1 1 1 1
A2501023 A2508025 F20444/2 A2517007 A4517002 A2501015 A2527007 A1501132 G23410 F23409 A2019025 F24509
SCREW NUT LIFTING PLATE EYE BOLT HYDRAULIC MOTOR SCREW SEAL WASHER O-RING MAIN SHAFT MOTOR SUPPORT SPRING WASHER SPACER
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SAFETY SPARE PARTS DRAGFLOW S.r.l. produces dredging pumps, pumps, they’re equipment for abrasive and heavy job. These kinds of
applications naturally wear the consumable of pumped the machine. wearing ofby thelittle consumable parts will get the performances of the machine lower suchparts as the solid The materials little will be less. To avoid to stop the equipment and lost time, DRA DRAGFLOW GFLOW S.r.l. S .r.l. qualified as your expert witness suggests to keep ready at site or placed in your workshop the following spare parts parts : POS. 6 13 16 17 19 20 21 22
Q. 1 1 1 1 1 1 1 1
PART NUMBER NUMBER F42939 A1501129 A1001097 A1001098 A1003010 A6503044 A1501098 A6503044
DESCRIPTION WEARING SPACER O-RING BALL BEARING BALL BEARING THRUST BEARING SEAL O-RING SEAL
23 24 25 26 28 36 39 40 41 43 44 45 46 47 49 50 51 53 56 58 61 83
1 1 1 1 1 1 1 1 1 1 2 1 1 1 3 1 2 1 1 1 1 1
A1501108 F42936-1 A1501096 F23171 A1501097 A6503005 F20632 F20620 A2501027 F20633/1 A1501130 F20631 F20619 F20617 A1502114 F24854/G A6503011 A6503048 F42938 A1002085 A1001086 A1501132
O-RING LOWER SHAFT SLEEVE O-RING GREASE SPACER O-RING UPPER SHAFT SLEEVE AGITATOR NUT AGITATOR AGITATOR SCREW AGITATOR CONNECTIVE CONNECTIVE O-RING AGITATOR AGITAT OR SPACER LOWER WEAR PLATE IMPELLER IMPELLE R SEAL DISCHARGE ADAPTER Ø150 SEAL SEAL LOWER SEALS FLANGE ROLLER BEARING BALL BEARING O-RING
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pg.
21
Hydraul draulii c pump Hy
H Y 35 A /B
Technical specifications: Model: A Capacity: 100 - 120 m /h Head: 20 - 28 m Weight: 500 Kg Cross section: 35 mm Impeller: 2 vanes closed /
B 140 - 170 m /h 14 - 20 m 515 Kg 35 mm 435 mm 2 vanes closed / 435 mm
Bore:
100
Motor : Speed: Output: Need of oil: Oil pressure: Motor displacement: displacement:
980 - 1180 r.p.m. 980 - 1180 r.p.m. 18.5 - 26 Kw ( 25 - 35 HP ) 18.5 - 26 Kw ( 25 - 35 HP ) 54 - 65 L/min 54 - 65 L/min 210 - 250 bar 210 - 250 bar 55 c.c. 55 c.c.
mm
150
mm
Materials: Main body: spheroidal cast iron GS500. Motor housing: cast iron GS5. Wearing parts: high chrome Main shaft: austempering NiCrMo4 steel. Seals: Seals motor zone: n° 2 rubber lip seals. Seals impeller zone: n° 1 polyurethane V-RING, n° 3 rubber lip seals, n° 2 PTFE lip seals with stainless steel spring ( alternate ). Performance curves:
Dimensions: A (mm)
1210
B (mm)
420
C (mm)
540
D (mm) E (mm)
667 Minimum height level
323
F (mm)
327
G (mm)
380
H1 (mm)
270
H2 (mm)
145
I (mm)
818
Drag flo flow w Srl – Vi a Pas Pas ubio, 40 – 37069 Villafranca Villafranca (VR ) Italy Italy Tel: +39 0456304521 – Fax: +39 0456335758 E -ma -mail: il: info@ dragflo dragflow.it w.it – www.dragf lo low.it w.it
