INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR PROGRESSIVE CAVITY PUMPS

Iom-01 Issue: 06/Jul/02 Page 1

FOREWORD
Thank you for your patronage of Roto Pumps Ltd. We are happy to inform you that your Roto Progressive Cavity Pump has been designed, manufactured & tested to give you a long, smooth and trouble-free operation. To get the best performance from the equipment we request you to carefully study the manual before, during and after installation of the pump. This manual is an essential part of the equipment and should be available at all times to the plant personnel and kept in a safe place in the plant premises. Should you have any doubts or queries, please do not hesitate to contact our nearest dealer or service center. Our experienced engineers would be happy to offer you expert advice. Should any of the following considerations be overlooked, the safety of personnel and satisfactory operation of the pump may be endangered. For your ready reference, our contact details are mentioned at the end of this manual. 1. GENERAL 1.1 1.2 1.3 1.4 1.5 Adequate ventilation must be provided in order to disperse dangerous vapours when pump is handling harmful or objectionable material. Adequate lighting should be provided to ensure effective maintenance. Usage with certain products may need a hosing facility to drain the pump to ease and simplify maintenance. Suitable arrangement should be provided to carry out gland draining. Adequate space must be provided for dismantling of the pump as per the dimensional drawing of the pump. (Refer enclosed dimensional drawing.)

2.

STORAGE & HANDLING 2.1 HANDLING For safe handling during installation and maintenance the following four points must be taken care of to avoid any damage to the component(s) or injury to personnel: 1. For lifting and assembling, use suitable lifting tackle and slings, if the pump or any of its components weigh more than 20 kg. 2. The position of slings will depend on specific pump model and mounted accessories. 3. If eyebolts are provided, they should be used for lifting. 4. Experienced personnel should carry out handling. 2.2 STORAGE Following points are advised for storage of pump and spares. 1. They should be kept in moisture-free area, preferably, with protective covering.

ROTO Std. No. RN-10-104-01

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR PROGRESSIVE CAVITY PUMPS

Iom-01 Issue: 06/Jul/02 Page 2

2. Pump should be stored after draining out the pumping liquid and preferably after flushing it with water. 3. A small amount of light oil should be injected in the stuffing box after loosening the gland. For food application pumps, use a compatible vegetable or edible grease. 4. Anti rusting oil or suitable agent must be applied on metallic parts to be stored. 5. Refer manufacturers instructions for storage of other items like gearbox, motor etc. 3 SYSTEM DESIGN AND INSTALLATION 3.1 SYSTEM DESIGN At the system design stage, consideration must be given for the provision of filler plugs and installation of non-return and/or isolating valves. ROTO PUMPS are normally installed in a horizontal position with base plates mounted on a flat surface, grouted in and bolted, thus ensuring firm fixing, thereby reducing noise and vibration. After bolting down the base frame, unit should be checked for correct alignment of the pump to its prime mover. If the pump is mounted in any other way than described above, confirmation of installation must be agreed with Roto Pumps Ltd. 3.2 ELECTRICAL 3.2.1 Electrical connections should only be made using equipment suitable for both rating and environment. Normally the Roto Pump should be installed with starting equipment arranged to give direct on line starting to ensure maximum starting torque. When the motor is being wired and checked for direction of rotation, ensure that the motor is not coupled with the pump. If any wiring or control device is to be fitted on the electrical equipment they must be set in accordance with their specific instructions. 3.2.2 Protection of all electrical equipment should be ensured for minimum safety requirements as per environment and fluid being pumped in accordance with applicable safety rules. 3.2.3 Earthing points of electrical equipments should be connected when the pump is fitted with electrical drives and it is essential that these be correctly connected as per the electrical equipment manufacturers recommendation. 3.3 DUTY CONDITIONS Your Roto pump has been selected based on process duty conditions (such as fluid, flow rates, pressure, temperature, etc.) at the time of order placement. Should any or more of these parameters change at the time of installation of the pump,

ROTO Std. No. RN-10-104-01

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR PROGRESSIVE CAVITY PUMPS

Iom-01 Issue: 06/Jul/02 Page 3

customer is requested to inform Roto Pumps Ltd. immediately. Roto Pumps will study the changed duty conditions and will advise/confirm in writing on the applicability of the installed pump and interest of safety, plant efficiency and pump life. 3.4 ROTATION After installation, should the direction of the pump rotation need to be changed, please consult Roto Pumps or its authorized representative for recommendation/ confirmation in writing. 3.5 GUARDS 3.5.1 In the interest of safety of personnel and in compliance with statutory requirement of various countries, the pump pulleys and couplings must be enclosed with proper guards.

3.5.2 Specific pumps may have auger feed screws with a wide suction flange. If the pump installation requires that these cannot be enclosed, care must be taken to ensure that personnel cannot gain access while the pump is in operation and emergency stop devices be fitted nearby. 3.6 IMPORTANT SAFETY MEASURES. 3.6.1 DOS When re-starting after a prolonged stoppage, always fill the pump with fluid and give a few turns to provide necessary lubrication. 2. Always use a pressure relief device on delivery line for system safety. 3. Use only direct on-line starters for meeting starting torque requirement of pump. 4. Uncouple pump while motor is being wired and checked for rotation to prevent dry running of pump. 5. Always consult Roto Pumps in case of any change in operating parameters, like temperature, viscosity, percentage of solids, liquid composition etc. 6. Always use genuine Roto spares for sustained pump performance and longer life of critical parts. 3.6.2 DONTS 1. Never run the pump in a dry condition even for a few revolutions otherwise the rotor will damage the stator immediately. 2. Never run the pump against a closed inlet or outlet valve. 3. Never use foot valve for slurry applications. 4. Never vary flow rate by throttling suction and delivery line. 5. Never exceed recommended pump speed. 6. Never reverse the recommended direction of rotation of pump without consulting Roto. 1.

ROTO Std. No. RN-10-104-01

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR PROGRESSIVE CAVITY PUMPS

Iom-01 Issue: 06/Jul/02 Page 4

7. Never use local made or spurious spares that look alike but do not meet material standards or dimensional accuracy affecting life of critical components and performance of pump. 8. Care is required when adjusting the gland while pump is running. 4. COMMISSIONING All nuts and bolts, securing flanges and base mounting fixtures, must be checked for tightness before operation. To eliminate vibration, the pump must be correctly aligned with the drive unit and the guards must be securely fixed in position. All the pipelines must be independently supported and use of expansion joints is desirable to eliminate the transmission of vibrations and stresses to the pipelines. When commissioning the plant, all the joints in the system must be checked thoroughly for leakage. If on starting, the pump does not appear to operate correctly, the pump must be shut down immediately and the cause of the malfunctioning must be established before operations are recommenced. It is recommended that depending upon plant system operation either a combined vacuum gauge and pressure gauge, or a vacuum gauge only, be fitted to the pump inlet port and a pressure gauge fitted to the outlet port to continuously monitor the pump operating conditions. It is further recommended that a pressure relief valve of adequate capacity should be installed on the discharge side of the pump. 5. START UP/RUNNING: 5.1 DRY RUNNING Pumps must be filled with liquid before starting (A threaded plug has been provided on the top of the pump housing for this purpose). The initial filling is not for priming purpose, but to provide the necessary lubrication of the stator until the pump primes itself. When the pump is stopped, sufficient liquid is normally trapped between the pumping elements to provide the necessary lubrication for restarting. If, however, the pump has been left standing for a long time or has been dismantled, it must be refilled with liquid and given a few turns before starting, to get sufficient lubrication between the rotor and stator. If the pumping liquid is hazardous, then extreme care must be taken while initial filling of the pump using all safety and precautionary measures. NEVER RUN THE PUMP IN A DRY CONDITION EVEN FOR A FEW REVOLUTIONS OTHERWISE THE STATOR WILL BE DAMAGED IMMEDIATELY. 5.2 GLAND PACKING 5.2.1 The pump is normally fitted with gland packing, which required final adjustment during initial running period. Under normal working conditions the gland rings are to be tightened in a manner to permit a slight drip from the gland. This enhances life of the shaft as well as of gland packing. It is important to note that the gland packing should never be over tightened to arrest the leakage completely. This can lead to excessive heat generation that can cause permanent damage to shaft and packing. Adjustment by

ROTO Std. No. RN-10-104-01

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR PROGRESSIVE CAVITY PUMPS

Iom-01 Issue: 06/Jul/02 Page 5

tightening should only be made when the pump is running. Indication of slight drip from the gland packing will only be evident if the pump is running delivery on gland or with suction on gland with a flooded suction. If the pump runs with a vacuum on the gland, a flushing connection (or greaser) with lantern ring is recommended. 5.2.2 5.3 Where lantern rings are fitted in stuffing box; the flushing liquid inlet or outlet should be connected for proper circulation of the liquid.

MECHANICAL SEAL When the pump is supplied with mechanical seal, it may be necessary to ensure proper flushing & quenching arrangement as per the seal manufacturers recommendations, enclosed with this manual.

5.4

GLAND GUARDS In the interest of safety of personnel and in compliance with statutory requirements of various countries, the pumps are fitted with gland-guards that can be easily removed for adjustment of gland sealing. It is responsibility of the user to make sure that the guards are placed back in position after necessary adjustments have been made.

5.5

PUMP OPERATING TEMPERATURE The surface temperature range depends upon factors like ambient temperature and temperature of the fluid being pumped. If the external pump surface temperature goes above 500C, personnel must be made aware of this and suitable warnings must be issued or guarding must be employed.

INSPECTION 6.1 ADJUSTMENT OF GLAND PACKING The gland packing should be inspected every day after starting the pump. Remove the gland guards to check the leakage. If the sealing is not proper, tightening or loosening of gland nuts to attain the preferred level of sealing must adjust it. Excessive tightening should be avoided, as it would result in excessive heat generation leading to permanent damage of both the packing and the drive shaft. Experienced personnel should carry gland adjustment carefully so that safety of the personnel is not endangered. 6.2 PERIODIC INSPECTION To avoid unexpected failure of the pump, it is important that the pump is periodically dismantled and routine inspection of the pump is carried out as follows:

ROTO Std. No. RN-10-104-01

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR PROGRESSIVE CAVITY PUMPS

Iom-01 Issue: 06/Jul/02 Page 6

1. 2.

Inspection of the pumping elements for wear and tear, after every six months or if the discharge falls below acceptable levels. Periodic bearings and universal joints inspection is necessary to maintain optimum performance. The most appropriate time to inspect is during periods of regular scheduled downtime for routine maintenance or for any other reason.

6.3

LUBRICATION The pump should be inspected periodically for lubrication of bearings to see if grease replenishment is required, and if so, grease should be added in accordance with the instructions given in assembly procedure.

6.4

PERIODIC CLEANING FOR FOOD PUMPS When a pump has been supplied for a food application it is important to ensure that the pump is cleaned prior to initial operation of the pump. The cleaning operation is executed on the pump when any of the following occur: 1. 2. 3. 4. When the pump is first commissioned for use. When any spare component is fitted into the wetted area of the pump. When the pump is used after a long time. When the pumping fluid has bacteriological contamination, cleaning frequency will depend on the pumping fluids properties.

A recommended Clean-In-Place (CIP) procedure is as follows: 1. 2. 3. 3. 2.5% W/V sodium hydroxide for 20 minutes at 80C. Clear water for 20 minutes at 80C. 2.0% V/V nitric acid for 20 minutes at 80C Clear water for 20 minutes at 80C.

These four stages constitute one cycle and it is recommended that this cycle be used for cleaning the pump before commencing the next batch of production. Once the pump has been commissioned the cleaning process will depend on the application. The user should ensure that appropriate cleaning procedure is followed. 7. MAINTENANCE OF WEARING COMPONENTS 7.1 ROTOR AND STATOR The wear rate of these components depends on many factors, such as product abrasiveness, speed, pressure etc. One or possibly both items will need to be replaced, when the pump performance has reduced to an unacceptable level. DRIVE SHAFT STUFFING BOX

7.2

ROTO Std. No. RN-10-104-01

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR PROGRESSIVE CAVITY PUMPS

Iom-01 Issue: 06/Jul/02 Page 7

The wear rate under gland area of the drive shaft depends on various factors like product abrasiveness, extent of tightening of the packing and speed of the pump. Periodic inspection and maintenance of the gland will maximize the life of the shaft. Replacement of the gland packing or both the gland packing and the drive shaft will be necessary when the shaft sealing becomes difficult to achieve. 7.3 UNIVERSAL JOINT Universal joints should be examined when the pump is dismantled for any reason or for routine maintenance during periods of regular scheduled equipment down time. The joints should be cleaned and renewed with fresh grease before assembly. Use only recommended grease as per specifications in this manual. 8. PUMPSET When a pump unit is disassembled and reassembled, it has to be ensured that the following steps, wherever applicable, are followed: 1. 2. 3. 9. Correct alignment of pump and driver. Use of appropriate couplings and bushes. Use of appropriate belts and pulleys.

EXPLOSIVE PRODUCTS/ HAZARDOUS AT MOSPHERE In certain instances, the product being pumped may be of a hazardous nature. In these installations, considerations must be given to provide suitable protection and appropriate warnings to safeguard personnel and plant.

10.

Enclosures: a) Pump assembly coding. b) Trouble shooting chart.

ROTO Std. No. RN-10-104-01

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR PROGRESSIVE CAVITY PUMPS TROUBLE SHOOTING

Iom-03 Issue: 06/Jul/02 Page 1

The Roto Progressive Cavity Pump has been designed and manufactured to give you smooth performance under the most arduous conditions. However, for some reason, should the pump not perform satisfactorily, listed below are various types of faults than can occur, their possible causes and suggested remedial measures. Even after performing the various remedial measures suggested, should the pump not function satisfactorily, please consult your nearest Roto Pumps dealer or service centre. FAULT 1. 2 3. 4 5 6. 7. 8. 9. 10. 11. 12. 13. 14. Pump fails to start No discharge Loss of capacity Loses priming after start. Pressure head too low Delivery fluctuates Drive is over loaded. Pump over heats Excessive power absorbed by pump. Noise & vibration. Excessive gland or seal wear. Seized pump. Bearings over heat Stator service life too short. POSSIBLE CAUSE 6, 12, 17, 26, 28, 29 1, 2, 3, 4, 5, 24 3, 4, 5, 6, 9, 10, 12, 13, 18, 20 3, 4, 5, 8, 9, 12 3, 5, 13, 20, 25 3, 4, 5, 6, 8, 12, 14 6, 8, 9, 11, 15, 18, 26, 27, 28 6, 9, 11, 18, 19, 26 6, 8, 11, 15, 18, 24, 26, 27 3, 4, 5, 6, 9, 15, 18, 20, 25, 30 7, 11, 16, 31 9, 12, 15, 26, 28 8, 15, 21, 22, 23 9, 18, 19, 26, 28

REASONS FOR FAILURE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Wrong direction of rotation Pump not primed. Air or vapor pockets in suction line. NPSH Available is too low Foot valve / strainer clogged. Viscosity greater than rated. Lantern ring plugged. Speed too high. Liquid temperature above rated figure. Viscosity lower than rated. Gland over tight. Gland under tight. Pump speed lower than rated. Belt drive slipping. Worn or loose bearings. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. Product entering packing area. Low voltage Pressure head too high. Stator not suitable to flow medium. Worn out rotor / stator. Wrong grade of lubricant. Moisture in lubricant. Excessive lubricant in bearings. Discharge valve blocked / clogged. Suction pipe leaks. Pump running dry. Specific gravity too high. Flow medium settles and hardens. Electric data of pump do not suit mains. Pump / drive mounting not firm. Gland flushing inadequate.

ROTO Std. No. RN -10-104-00

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR PROGRESSIVE CAVITY PUMPS.

SP-01-001-01 27-06-2001

SPECIAL INSTRUCTIONS FOR RNA SERIES

1. ROTATION The RNA/RNB Series pumps are capable of taking rotation in both the directions but if a change of direction is required, consult Roto pumps or its authorized agents before doing so. 2. LUBRICATION Bearings: Pumps should be inspected periodically to see if grease replenishment is required. If so, bearings should be cleaned and repacked with grease until the bearing chambers are one third full with grease. Use one of the following recommended or equivalent grease. 1. 2. 3. 4. SHELL Alvania R3 BP Energrease LS3 Castro Spheerol AP3 Mobilux 3

Universal Joints: The pin type universal couplings should be lubricated when the pump is dismantled due to some reason. To do so, pack entire space between the coupling rod head and rotor or drive shaft bore with one of the following recommended or equivalent grease, after cleaning the components. 1. 2. 3. 4. 3. Shell Alvania Grease 2 Mobilux 2 MP Grease 2 Castrol Spheerol AP2

PUMP HOUSING ASSEMBLY While assembling the pump housing care must be taken that the pump housing does not rub against the rotor or the coupling rod as the scratches may substantially reduce the life of the rotor/ coupling rod. Also ensure that the rotor is supported at a comfortable height and is not left freely hanging during assembly.

4.

ALIGNMENT OF BUSHES. For alignment of the coupling rod bush in the coupling rod use the marks made on the coupling rod and the bush for alignment of the elongated hole axis of the bush with the coupling rod axis. The alignment is extremely important as misalignment will make the pump noisy and can severely reduce the life of the coupling rod/ bush to the extent of instant snapping of the coupling rod on starting the pump.

ROTO PUMPS LTD.

PRODUCT MANAGEMENT GROUP 1

SPECIAL INSTRUCTIONS
Whenever there are Boot seal of EPDM material are recommended or used, please ensure that only following Silicone Grease Compound is used for such applications.

MOLYKOTE 7 COMPOUND
Or alternatively

OKS 1110 GREASE

The above Greases also comply with Food
Product Management Group Roto Pumps Ltd.

Applications.

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR PC PUMPS PUMP ASSEMBLY CODE "N" SERIES INDUSTRIAL P.C. PUMPS
1 R W K B N A D E A B C 6 0 1 2 4 B R J E H V 2 3 6 7 9 0 C M C S Z D S F F Z 1 3 5 B C D H J K N T V S Z / Z R N A A 0 3 1 R 7 C D 1 N 0 0 2 3 4 5 6 7 8 9 10 11 PUMP ASSEMBLY SEQUENCE 12 13 14 15 16 17 MAR. VAR. /

PUMP FEATURES BASIC CONSTRUCTION CODE PUMP SERIES PUMP CONFIGURATION CODE DESIGN VARIATION CODE PUMP SIZE PUMP STAGE

BASIC DESCRIPTION INDUSTRIAL, STANDARD, HORIZONTAL PUMP INDUSTRIAL PUMP WITH WIDE THROAT INDUSTRIAL PUMP WITH WIDE THROAT & BRIDGE BREAKER BARREL EMPTYING PUMP INDUSTRIAL DESIGN BARESHAFT, STRAIGHT THROUGH END COVER CLOSED COUPLED, STRAIGHT END PORT (BARREL PUMP) BARESHAFT, STRAIGHT END COVER WITH SHAFT SLEEVE FIRST DESIGN SECOND DESIGN (BARREL PUMP) THIRD DESIGN (LIGHT DESIGN) 01, 02, 03, 04, 05, 06, 07, 08, 09, 10 SINGLE STAGE DOUBLE STAGE FOUR STAGE NATURAL BLACK NITRILE BLACK

ELASTOMER MATERIAL

HIGH NITRILE BLACK EPDM BLACK CHLORO SULPHONATED RUBBER BLACK FLURO ELASTOMER BLACK SS 410 HCP ROTOR, SS 410 C/ROD, SS 410 HCP UG SHAFT SS 316 HCP ROTOR, SS 410 C/ROD, SS 410 HCP UG SHAFT

ROTATING PARTS MATERIAL

SS 316 UP ROTOR, SS 316 C/ROD, SS 316 SHAFT SS 316 HCP ROTOR, SS 316 C/ROD, SS 316 HCP UG SHAFT AISI 8620 CASE HARDENED HCP ROTOR, SS 410 C/ROD, SS 410 HCP UG SHAFT MARKET VARIATION CAST IRON, AS PER ASTM A 48 M, CLASS 225 (IS:210, FG 220) MILD STEEL (IS: 2062 GR. II) CAST STAINLESS STEEL CF 8 M AS PER ASTM A 351 FABRICATED STAINLESS STEEL AISI SS 316 MARKET VARIATIONS STANDARD

WETTABLE HOUSING PARTS MATERIAL

ROTOR MARK

MARK III MARK V ARAMID PACKING IMPREGNATED WITH PTFE HIGH TEMP. RESSITING LUBRICANTS LUBRICATED PTFE YARN PACKING GRAPHITED IMPREGNATED GLASS YARN PACKING LUBRICATED WITH MINERAL OIL
ARAMID PACKING IMPREGNATED WITH PTFE HIGH TEMP. RESISTING LUBRICANTS WITH LANTERN RING

SHAFT SEALING MATERIALS

LUBRICATED PTFE YARN PACKING WITH LANTERN RING

GRAPHITED IMPREGNATED GLASS YARN PACKING LUBRICATED WITH MINERAL OIL WITH LANTERN RING

SINGLE COIL SPRING, UNBALANCED, BI-DIRECTIONAL, SEMI-DIN 24960*, C Vs CER FACES SINGLE COIL SPRING MECH. SEAL, UNBALANCED, BI-DIRECTIONAL, SEMI-DIN 24960*, C Vs SiC FACES SINGLE COIL SPRING MECH. SEAL, UNBALANCED, BI-DIRECTIONAL, SEMI-DIN 24960*, SiC Vs SiC FACES SINGLE COIL, ELASTOMER. BELLOW SEAL, BI-DIRECTIONAL, DIN 24960, C Vs Cer FACES MARKET VARIATIONS

SLASH ADDITIONAL

OTHER MARKET VARIATIONS MARKET VARIATIONS

EXAMPLE 1 BASIC CODING WITHOUT MARKET VARIATION

ABOVE CODE DENOTES INDUSTRIAL "N" SERIES BARESHAFT PUMP SIZE 03 AND SINGLE STAGE, WITH STRAIGHT THROUGH END COVER CAST IRON WETTABLE HOUSING PARTS, CODE 7 ROTATING PARTS, NITRILE RUBBER STATOR, STANDARD ROTOR AND MECHANICAL SEAL (SINGLE COIL SPRING, UNBALANCED, BIDIRECTIONAL, SEMI-DIN 24960*, C Vs CER FACES)

DISMANTLING INSTRUCTIONS FOR RNAA-034/042/044/051/052/054/061/062/064/071/072/081/082/091 092/101/102 PUMPS

AD-01-006-00
07.09.2001

DISMANTLING INSTRUCTIONS
Before dismantling, isolate all electrical circuits. Close all isolation valves on the suction and discharge lines to the pump for prevention of liquid escaping from the pipe work system . The persons carrying out the work should be adequately trained in general workshop practice, relevant to the class of work involved & taking care of safety measures.

STEP 1

DESCRIPTION Unscrew the Domed Nuts (22) and Spring Washers (23) fitted on the End Cover (5310) with Tie Rods (7710). Remove end cover. Unscrew Nuts (20), and Tie Rods (7710). Remove Middle Support Foot (0610) and Tie Rods (7710) from the Pump Housing (5010), while supporting Pump Housing from beneath. To remove Stator (2220) from the Rotor (2500), hold the stator stationary and rotate the pump coupling / pulley on the Shaft (3200) in clockwise direction looking from drive end. If Stator (2220) offers some resistance pour little water or soap solution through the opening to ease the stiffness. Unscrew the four Domed Nuts (16) with Spring Washers (17) and withdraw the Pump Housing (5010), ensuring it does not rub against universal joint assembly and rotor. Rotor may be protected by covering with some soft material like cloth. Slip out the Boot Seal Retainer (2810) and push back the Pin Retainer Sleeve (2820) over the Boot Seal (1510) and slide it over Coupling Rod (2610) from the rotor end. Remove Boot Seal (1510). Knock out the Coupling Rod Pin (2910) and withdraw the Rotor (2500) and remove the O-rings (12). Repeat the same operation at the other end of the coupling rod and withdraw the coupling rod from the shaft head. Remove the coupling / pulley and the Shaft Key (02) from the shaft. Unscrew the four Hex. Head Screws (14) from the Bearing Cover (0410) and remove the bearing cover. Open the Lock Washer (08) and unscrew the Bearing Lock Nut (07). Unscrew the Grub Screw (24) that holds the Grease Seal Housing (0420). Loosen the Gland Nuts (19). Press out the Shaft (3200) along with Stuffing Box (5800) and Gland (5410) or Mechanical Seal Housing (5861), Ball Bearings (05) and the Bearing Spacer (8510) from the Bearing Housing (0110). Extract the Outer Bearing (05) and the Internal Circlip (06) from the bearing housing. Page 1 of 5

DISMANTLING INSTRUCTIONS FOR RNAA-034/042/044/051/052/054/061/062/064/071/072/081/082/091 092/101/102 PUMPS

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Remove the Bearing Spacer (8510), Inner Bearing (05), Grease Seal Housing (0420) and Stuffing Box (5800) or Mechanical Seal Housing (5861), as applicable, from the Shaft (3200). In case of mechanical seal, unscrew the grub screws in the drive collar and take out rotating mechanical seal components. Also take out the Stationary Seat from the Mechanical Seal Housing (5861), by applying even pressure from the back face of stationary seat.

10

Clean all the parts and check for any wear / damage. The worn out parts should be replaced with original ROTO spares. In order to store dismantled parts, use suitable anti-rust compound on metallic surfaces of the components

Page 2 of 5

ASSEMBLY INSTRUCTIONS FOR RNAA-034/042/044/051/052/054/061/062/064/071/072/081/082/091 092/101/102 PUMPS

AD-01-006-00
07.09.2001

ASSEMBLY INSTRUCTIONS
STEP 1 DESCRIPTION Place internal circlip (06) in its groove in bearing housing. Insert ball bearing (05) filled with grease and tighten it with bearing cover with the help of Hex Head Screws (14). Assemble stuffing box (5800) with gland (5410) over the shaft (3200) close to the head. In case of mechanical seal, proceed as following. Insert the Stationary Seat along with O-ring in Mechanical Seal Housing (5861), applying even pressure on the face of seal. In case of Stationary Seat with Teflon o-ring, press the seat with o-ring in mechanical seal housing (5861), placing under a small hand press or a drilling machine spindle, keeping a soft pack on the stationary seat face. Now insert drive collar with rotating components of mechanical seal from drive end of the shaft towards shaft head. Next, measure distance L from the face of stationary seat to the open end face of mechanical seal housing (as shown in drg. No. RN-10-163-00). If L1 is the operating length of mechanical seal locate driving collar at a distance C from shaft step ,as shown, where C= L-L1+ 5 mm. For RNAA-034/042/044/051/052/054/061/062/071 Pumps. C= L-L1+ 6mm. For RNAA-064/072/081/082/091/092 Pumps. C= L-L1+ 8mm. For RNAA-101/102 Pumps Fix the driving collar in place on the shaft by tightening with grub screws. 3 Insert grease seal housing (0420) with grease seal (04) fitted onto the shaft. Insert inner ball bearing filled with grease over the shaft and also insert bearing spacer (8510) on the shaft. Offer sub-assembly 3 to the sub-assembly 1 horizontally so that the shaft extension projects out from the bearing cover (0410). Now press the Shaft (3200) from pump end side so that the inner Bearing (05) acquires its position on the shaft. Unscrew 4 hex. Head screws (14) and remove the bearing cover (0410) from the bearing housing (0110). Lock the bearings with locknut (07) and secure it with locking washer (08).

4 5 6 7

ASSEMBLY INSTRUCTIONS FOR RNAA-034/042/044/051/052/054/061/062/064/071/072/081/082/091 092/101/102 PUMPS

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Fill the Bearing Cover (0410) with the grease covering approx. one third of its space. Lock the bearing assembly with bearing cover, fitted with grease seal (03), by tightening Hex. Head screws (14). Place the grease seal housing (0420) in its position and lock it with grub screw (24). If coupling Rod Bush (2710) is to be replaced, use the marks made on the Coupling Rod Head and the Bush for alignment of the elongated hole axis of the Bush with the Coupling Rod axis and press-in the Bush in Coupling Rod Head, centrally along its length. Connect coupling rod (2610) to the Shaft head and to the Rotor head, filling entire space between coupling rod head and Shaft head / Rotor head with recommended lubricant and adopting the reverse procedure as described in step 4 of the disassembly instructions by locating Seal Ring (1610), Coupling Rod Pin (2910), Boot Seal (1510), Pin Retainer Sleeve (2820), and Boot Seal Retainer (2810) in place.

9 10

11

Offer pump housing (5010), to the Bearing Housing (0110) with O ring (10) in its position and fitting Stuffing Box (5800) or Mechanical Seal Housing (5861), as applicable, in between and secure with four domed nuts (16) with spring washers (17). Wet the stator (2220) and thread it over the rotor (2500), holding shaft (3200) against rotation till stator butts with pump housing (5010). For RNAA034/044/054/064/072 pumps, place O-Ring (11) and Stator support Ring (6220) between Stator and Pump Housing and Stator and End Cover (5310). Offer Middle Support (0610) to Pump Housing, matching tapped holes for Tierods. Insert Nuts (20) in the Tie-rods for tightening Middle Support. Screw Tie Rods (7710) in pump housing (5010) from Nuts (20) side, and tighten Middle Support evenly with Nuts (20). Insert end cover (5310) in its position over the tie rod ends and secure it with the domed nuts and spring washers. Recheck that all the fasteners are fully tightened and for the completeness of the assembly as per relevant drawing.

12

13

14

15

ASSEMBLY INSTRUCTIONS FOR RNAA-034/042/044/051/052/054/061/062/064/071/072/081/082/091 092/101/102 PUMPS

AD-01-006-00
07.09.2001

Reference Documents: 1. CS -01-006-01 Cross-sectional drawing for RNAA-034/044/054/064/072 Pumps 2. CS -01-004-01 Cross-sectional drawing for RNAA-042/051/052/061/062/071 /081/082/091/092/101/102 Pumps 3. RN-10-163-00 4. SP-01-001-01 Mechanical Seal and Stuffing Box Arrangement Special Instructions for RN series Pumps