IMO OptiLine ACG8 Original Operating Manual

ACG8 2018.01 en-GB, ID-No.: 163-043/A

Original Operating Manual

Before commencing any work, read this instruction carefully! Failure to comply with
these instructions may cause damage and personal injury!

!

Screw pumps

OptiLine ACG8

Contents Page

Introduction 2
Safety 2
Installation 5
Start-up 8
Trouble shooting 9
Maintenance and Service 11
List of components 12
Exploded View/Ordering code 13
Service intervals 14
Dismantling and reassembling the pump 15
Dismantling 16
Reassembly 21

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Order data sheet Technical specications, conditions of operation

Technical description Technical specications, operating limits

Supplier documentation Technical documentation for parts supplied by

subcontractors, e.g. drive system, coupling or
auxiliary operating system.

Spare parts list Ordering spare parts

Declaration of conformity Conformity with standards,

Content of the declaration of conformity

Other applicable documents

Introduction

ATTENTION

ATTENTION

Safety

The manufacturer accepts no liability for damages caused by disregarding any of the documentation.

Intended use

• Only use the pump to pump the agreed pumped liquids (→ order data sheet).

• Adhere to the operating limits.

• Avoid dry running:
– Make sure the pump is only operated with, and never without, pumped liquid.

• Avoid cavitation:

– Open the pressure-side tting completely.

• Avoid damage to the motor:

– Do not switch on themotor more that themaximumpermissible number of times per hour (→ manufac-

turer’s specications).

• Consult the manufacturer about any other use of the pump.

• Pumps delivered without a motor must be assembled into a pump unit according to the provisions of

EC Machine Directive 2006/42/EC.

Prevention of obvious misuse (examples)

• Note the operating limits of the pump with regard to temperature, pressure, viscosity, ow rate and motor

speed (→ order data sheet).

• When using auxiliary systems, ensure there is a continuous supply of the appropriate operating medium.

• Do not operate the pump while the pressure-side tting is closed.

• Only select the setup type according to this operating manual. For example, the following are not allowed:
– Hanging pumps in the pipe
– Overhead installation
– Installation in the immediate vicinity of extreme heat or cold sources

General safety instructions

Observe the following regulations before carrying out any work.

Product safety

The pump has been constructed according to the latest technology and recognized technical safety rules.
Nevertheless, operation of the pump can still put the life and health of the user or third parties at risk or dam­age the pump or other property.

• Only operate the pump if it is in perfect technical condition and only use it as intended, remaining aware of

safety and risks, and adhere to the instructions in this manual.

• Keep this manual and all other applicable documents complete, legible and accessible to personnel at all

times.

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• Refrain from any procedures and actions that would pose a risk to personnel or third parties.

• In the event of any safety-relevant malfunctions, shut down the pump immediately and have the malfunc­tion corrected by the personnel responsible.

• In addition to the entire documentation for the product, comply with statutory or other safety and acci­dent-prevention regulations and the applicable standards and guidelines in the country where the system is
operated.

Obligations of the operating company

Safety-conscious operation

• Ensure that the following safety aspects are observed and monitored:
– Intended use
– Statutory or other safety and accident-prevention regulations
– Safety regulations governing the handling of hazardous substances
– Applicable standards and guidelines in the country where the pump is operated

• Make personal protective equipment available.

Qualied personnel

• Make sure all personnel tasked with work on the pump have read and understood this manual and all other

applicable documents, especially the safety, maintenance and repair information, before they start any work.

• Organize responsibilities, areas of competence and the supervision of personnel.

• Ensure that all work is carried out by specialist technicians only:
– Fitting, repair and maintenance work
– Work on the electrical system

• Make sure that trainee personnel only work on the pump under the supervision of specialist technicians.

• Persons who have an implanted pacemaker:
– Must stay away from the pump with magnetic coupling and parts of the magnetic coupling
– May not work on or with any of the magnetic parts

Safety equipment

• Provide the following safety equipment and verify its functionality:
– For hot, cold and moving parts: on-site safety guards for the pump
– For possible electrostatic charges: provide the necessary grounding
– If there is no pressure relief valve in the pump: Provide an appropriate safety valve on the pressure

side between the pump and the rst shut-off device

Warranty

• Obtain the manufacturer’s approval prior to carrying out any modications, repairs or alterations during the

warranty period.

• Only use genuine parts or parts that have been approved by the manufacturer.

Drive system

For pumps delivered without a drive system, comply with the following requirements for the drive system:

• When using three-phase asynchronous motors, observe IEC 60034-30-1.

• Power of the drive according to EN ISO 5199 is recommended (EN ISO 5199 also applicable for drives of

screw pumps).

• Use coupling guard with the following requirements:

– Fastening elements must be connected to the pump unit in undetachable design (cannot get lost).

– Safety distances against the reaching of hazardous areas according to EN ISO 13857 must be

complied with.

Obligations of the operating company

• All directions given on the pump must be followed (and kept legible), e.g. the arrow indicating the sense of

rotation and the markings for uid connections.

• Pump, coupling guard and components:
– Do not step on them or use as a climbing aid
– Do not use them to support boards, ramps or beams

– Do not use them as a xing point for winches or supports

– Do not use them for storing paper or similar materials
– Do not use hot pump or motor components as a heating point
– Do not de-ice using gas burners or similar tools

• Do not remove the safety guards for hot, cold or moving parts during operation.

• Use personal protective equipment whenever necessary.

• Only carry out work on the pump while it is not running.

• Isolate the motor from its supply voltage and secure it against being switched back on again when carrying

out any tting or maintenance work.

• Reinstall the safety equipment on the pump as required by regulations after any work on the pump.

• With an implanted pacemaker:
– Stay at least 1 meter away from the pump with magnetic coupling or parts of the magnetic coupling.
– Do not work with or on the magnetic parts.

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Specic hazards

Hazardous pumped liquids

• Observe the safety regulations for handling hazardous substances (e.g. hot, ammable, poisonous or po­tentially harmful) when handling hazardous pumped liquids.

• Use personal protective equipment when carrying out any work on the pump.

• Noise level:
– Check individual pump series noise level in respective Product Description

Magnetic eld

The magnetic eld of the magnetic coupling can destroy products that are sensitive to magnets.
These include:

• Pacemakers

• Plastic identity cards with magnetic strips

• Credit and check cards

• Electric, electronic and precision mechanical devices (such as mechanical and digital clocks, pocket

calculators, hard disks)

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max. 90°

min. 60°

Fig 2. Lifting the pump

Design limitations and technical data for each pump
are found in the Product description. Installation of IMO
AB low pressure pumps does not require special skills.
However, these instructions presume that the work is

carried out by experienced tters!

11

Failure to comply with these instructions

may cause damage and personal injury

Transport and storage

Always protect the pump against ingress of water
and other impurities. Store the pump in a clean, dry
and warm environment. The pump is delivered with
the internals oiled and with protective covers over the
pipe connections and drain openings. These covers
should remain in place for as long as possible during
the mounting and installation procedure but must be
removed before start up.

Lifting of pump

Lifting of the complete pump unit with the lifting device
attached to the motor, should be avoided as the motor’s
lifting provisions may not be able to carry the combined
weight of the pump and motor.

12

All pumps should be lifted with straps

securely attached to the pump or pump
unit, so that the center of gravity is located
between the straps in order to avoid
tipping of the pump.

Strainer

The pump has to be protected from foreign matters
such as weld slag, pipe scale, etc., that could enter the
pump via the suction line. If the cleanliness of the sys­tem cannot be guaranteed, a strainer must be installed
in the inlet pipe near the pump. For practical reasons
a suction strainer with 0.8-2.0 mm mesh openings is
recommended.
The size of the strainer should be selected so that it is
large enough to allow adequate pressure at the pump
inlet. The pressure drop across the strainer should
preferably not exceed 0.1 bar at max. ow rate and nor­mal operating viscosity. A vacuum gauge between the
strainer and the pump inlet is recommended to indicate
when the strainer needs cleaning.

13

All work carried out on the pump has to be

performed in such a manner that risks for
personal injury are observed.

14

Lifting a complete pump unit, using

slings or hooks attached to the pump or
connecting frame may be dangerous since
the centre of gravity of the pump unit may
be higher than the points of attachement.

Fig. 3 Strainer

Installation

Fig 1. Keep dry and clean

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Fig. 6 Deaeration

Pipe connections

The pipe work shall be installed and supported so that
no pipe stresses are transferred to the pump body.
The pipe forces and torque transferred to the pump
shall be in accordance with ISO 14847. The pipe work

should be tight in order to avoid leakage and inltration

of foreign particles and/or air. Shut off valves should be
installed in both suction and discharge pipes, so that
the pump can be hydraulically isolated.

Suction line

The suction pipe should be designed so that the total

pressure drop, measured at the pump inlet ange, does

not exceed the suction capability of the pump. Make a
proper calculation of the suction line including compo­nents such as valves, strainer, pipe bends etc. Gener­ally, the pressure drop in the suction line should be as
low as possible, which is achieved if the suction pipe is
short, straight and has a suitable diameter. The velocity
in the suction line should be kept in the range 0.5 - 1.2
m/s. For L.O. circulating systems, we recommend to
keep it as low as possible. The suction line must be

equipped with a port that allows lling the pump before

start.

Discharge line

The discharge line should be dimensioned to keep the
velocity in the range 1 - 3 m/s.

Deaeration

In installations with negative suction head, where the
pump might be started against a pressurized system, a

deaeration pipe with an orice (2-3 mm is recommend­ed) has to be installed. The deaeration pipe should be

connected to the outlet pipe’s highest point. This must
also be installed when the pump is used as a stand-by
pump.

Liquid trap

In some mounting arrangements the pump may not
retain the liquid at stand still. In such installations the
suction pipe should be arranged so it forms a liquid trap

together with the pump, keeping the pump half lled

with liquid.

Fig. 4 Pipe connections

Fig. 5 Suction Line

15

When handling liquids that may harm skin

use gloves and/or protective clothing

16

When handling liquids shich may involve

re hazards appropriate precautions to

avoid danger are to be taken.

Fig. 7 Liquid trap

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bar

Gauges

Gauges for monitoring the pump’s working conditions
are recommended. These gauges should be placed

readable as close to the pumps in- and outlet anges

as possible. On the ACG Optiline standard pumps there
are gauge connections for both in- and outlet.

Pressure relief valve

All systems with screw pumps must be equipped with
a pressure relief valve installed immediately adjacent
to the pump. In the standard versions of IMO ACG
Optiline pumps, this pressure relief valve is an integral
part of the pump to protect the system against excess
pressure. When liquid is circulated through the valve it
heats up in proportion to the set pressure level and the
percentage of by-passed liquid. 100% bypass can only
be tolerated for less than about 3 minutes, 50 %by-pass
generally for unlimited periods of time. If more than

50% recirculation is anticipated, a value specic to each

application should be determined by closely monitoring
the pump body temperature. If the pump is operating in
line with a separate pressure control valve

(see g. 9), the setting of the relief valve should be high

enough so as not to interfere with the control valve.
Likewise, if two pumps are operating in parallel, the
setting should be such that interference between the
two valves is avoided.
Also remember that a total bypass by the pumps inter-

nal relief valve will cut of the cooling ow to the pumps

magnetic coupling and cause an overheating with
destroyed magnets as a result quite fast.

17

Oil leakage may make the oor slipper y

and couse personal injury.

Fig. 8 Gauges

Fig. 9 Pressure Relief Valve

Fig. 10 External control with presssure relief valve

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Pressure testing and ushing

The system must be ushed and pressure tested before

connecting the pump. If corrosive liquid, such as water
is used, the system must be thoroughly drained, dried
and protected against corrosion after having been

ushed.

Before starting:

After installation and whenever it can be assumed that
the pump has been emptied, the pump must be thor-

oughly lled with liquid. See g 11.

18

Make sure the prime mover is locked out

and can not be started accidentally.

Direction of rotation

When the pump is ready to be started, switch the motor

briey on and off and check that the drive motor rotates

in the correct direction as indicated by the rotation
arrow. The arrow is placed on the side of the front cover
5010 as well as on riveted steel plates on the connect­ing frame 003.

Differential pressure

Differential pressures bellow 1 bar is strictly forbidden
as the magnetic coupling under these conditions may

loose its cooling ow and cause an overheating of the
magnetic coupling with a risk of a potential re as a

result. We do strongly recommend magnetic coupled
pumps to be equipped with a differential pressure
monitoring device that stops the pump automatically if
the differential pressure for some reason should drop to
below 1 bar.

Air in the pumped uid

It is forbidden to use the ACG Optiline pump with uids

that contains more than 0,2% of air due to the risk of
ignition during an eventual overheating of the pump.

Fig. 11 Filling the pump

Fig. 12 Direction of rotation

Fig. 13 Differential Pressure

19

Don't mix up with arrow for inlet and

outlet!

Startup

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Problem Cause What to do

Wrong direction of rota­tion

- Electric cables to motor wrongly
connected.

Reverse the terminal connection on
electric motor.

20

Connecting and disconnec-

ting of electric cables must
be done only by personnel
authorized to do such
work.

The pump cannot be
primed

- Wrong direction of rotation.

- Suction line is not open or pressure
drop in the suction line is too high.

- Major air leakage into the suction
line.

- The pump cannot evacuate the air
through the discharge line due to
excessive counter pressure.

See above.

Check all components in suction line.
The inlet condition should be checked
with a vacuum gauge at the pump inlet.

Check the suction line.

See the chapter on Deaeration

(see page 22).

No ow - The pump is not primed.

- The pressure relief valve is set be­low the counter pressure.

See above.

Readjust the pressure relief valve to a
value above counter pressure.

Flow too low - The pressure relief valve is set too

low (Discharge pressure also low).

- Something is restricting the ow in

the suction line. (This would usually

cause noise).

- The pumped liquid contains a signif­icant amount of compressible gas,
such as free air. (This would usually

cause noise).

Readjust the pressure relief valve

Check all components in the suction
line (strainers, valves etc.).

See the chapter on Noise and Vibra-

tion. ( Page 11).

Pressure too low - The pressure relief valve is set too

low.

- Counter pressure in the discharge
line is too low due to a major leak­age.

- The valve piston is stuck in open
position.

- Something is restricting the ow in

the suction line. (This would usually

cause noise).

- The pumped liquid contains a signif­icant amount of compressible gas,
such as free air. (This would usually

cause noise).

- A too small pump has been chosen.

Readjust the pressure relief valve.

Check the components in the discharge
line inclusive the recipients.

Check the valve. See Maintenance and
Service instruction for respective pump.

Check all components in the suction
line (strainers, valves etc.).

See the chapter on Noise and Vibra­tion. (Page 11).

Contact your IMO AB representative.

Trouble shooting