INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS

FOREWORD base plates mounted on a flat surface, grouted in and bolted,

Thank you for your patronage of the Roto Pumps Ltd. thus ensuring firm fixing, thereby reducing noise and
We are happy to inform you that your Roto progressive vibration.
Cavity Pump has been designed, manufactured & tested
to give you a long, smooth and trouble-free operation. After bolting down the base frame, unit should be checked
To get the best performance form the equipment we for correct alignment of the pump to its prime mover.
request you to carefully study the manual before, during
and after installation of the pump. This manual is an If the pump is mounted in any other way than described
essential part of the equipment and should be available above, confirmation of installation must be agreed with
at all times to the plant personal and kept in a safe place ROTO.
in the plant premises.
Should you have any doubts or queries, please do not ELECTRICAL –
hesitate to contact our nearest dealer or service center. Electrical connections should only be made using equipment
Our experienced engineers would be happy to offer to suitable for both rating and environment. Normally the
you expert advice, should any of the following ROTO Pump should be installed with starting equipment
considerations be overlooked, the safely of personal arranged to give direct on line starting to ensure maximum
and satisfactory operation of the pump may be starting torque. When the motor is being wired and checked
endangered. for direction of rotation, ensure that the motor is not coupled
For your ready reference, our contact details are with the pump. If any wiring or control device is to be fitted
mentioned at the end of this manual. on the electrical equipment they must be set in accordance
with their specific instructions.
GENERAL
1. Adequate ventilation must be provided in order to Protection of all electrical equipment should be ensured for
disperse dangerous vapors when pump is minimum safety requirements as per environment and fluid
handling harmful or objectionable material. being pumped in accordance with applicable safety rules.
2. Adequate lighting should be provided to ensure
effective maintenance. Earthing points of electrical equipments should be connected
3. Usage with certain products may need a hosing when the pump is fitted with electrical drives and it is
facility to drain the pump to ease and simplify essential that these be correctly connected as per the
maintenance. electrical equipment manufacturer’s recommendation
4. Suitable arrangement should be provided to carry
out gland draining. DUTY CONDITIONS
5. Adequate space must be provided for dismantling Pumps should only be installed on duties for which ROTO
of the pump as per the dimensional drawing of the has specified materials of construction, fluid, flow rates,
pump. (Refer enclosed dimensional drawing.) pressure, temperature, speed etc. If the duty is changed,
ROTO’S recommendations should be sought immediately in
the interest of safety, plant efficiency and pump life.
STORAGE & HANDLING
HANDLING: For safe handling during installation and
maintenance the following four points must be taken care of ROTATION
Consult ROTO or its authorized representative if the
to avoid any damage to the component or personnel injury:
direction of rotation of pump has to be changed after
1. For lifting and assembling, use suitable lifting
tackle and slings, if the pump or any of its installation.
component weighs more than 20 kg.
GUARDS
2. The position of slings will depend on specific pump
model and mounted accessories In the interest of safety of personnel and in compliance with
statutory requirement of various countries, the pump pulleys
3. If eyebolts are provided, they should be used for
and couplings must be enclosed with proper guards in the
lifting.
4. Experienced personnel should carry out handling. interest of safety of personnel.
Specific pumps may have auger feed screws with a wide
STORAGE: Following points are advised for storage of
suction flange. If the pump installation requires that these
pump and spares.
1. The Pump should be kept in moisture-free area, cannot be enclosed care must be taken to ensure that
personnel cannot gain access while the pump is in operation
preferably, with protective covering.
and emergency stops device must be fitted nearby.
2. Pump should be kept after draining out the
pumping liquid and preferably after flushing it with
IMPORTANT SAFETY MEASURES
water.
DO’S
3. A small amount of light oil should be injected in the
1. Always fill the pump with fluid and give few turns
stuffing box after loosening the gland. For food
to provide necessary lubrication before starting
application pumps, use a compatible vegetable or
when subject to prolonged stoppage.
edible grease.
2. Always use a pressure relief device on delivery
4. Anti rusting oil or suitable agent must be applied line for system safety.
on metallic parts to be stored. 3. Use only direct on-line starters for meeting starting
5. Refer manufacturer’s instructions for storage of torque requirement of pump.
other items like gearbox, motor etc. 4. Uncouple pump while motor is being wired and
checked for rotation, to prevent dry running of
SYSTEM DESIGN AND INSTALLATION pump.
SYSTEM DESIGN - At the system design stage, 5. Always consult ROTO in case of any change in
consideration must be given for the provision of filler plugs operating parameters, like temperature,
and installation of non-return and/or isolating valves. ROTO viscosity, percentage of solids, liquid composition
PUMPS are normally installed in a horizontal position with etc,
 INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS

6. Always use genuine ROTO spares for sustained tightened to arrest the leakage completely. This can lead to
pump performance and longer life of critical parts. excessive heat generation that can cause permanent
DON’TS damage to shaft and packing. Adjustment by tightening
1. Never run the pump in a dry condition even for a should only be made when the pump is running. Indication
few revolutions otherwise the rotor will damage the of slight drip from the gland packing will only be evident if the
stator immediately. pump is running delivery on gland or with suction on gland
2. Never run the pump against a closed inlet or outlet with a flooded suction. If the pump runs with a vacuum on
valve. the gland, a flushing connection (or greaser) with lantern ring
3. Never use foot valve for slurry applications. is recommended.
4. Never vary flow rate by throttling suction and
delivery line. Where lantern rings are fitted in stuffing box; the flushing
5. Never exceed recommended pump speed. liquid inlet or outlet should be connected for proper
6. Never reverse the recommended direction of circulation of the liquid.
rotation of pump without consulting ROTO.
7. Never use local made or spurious spares that look MECHANICAL SEAL - When the pump is supplied with
alike but do not meet material standards or mechanical seal, it may be necessary to ensure proper
dimensional accuracy affecting life of critical flushing & quenching arrangement as per the seal
components and performance of pump. manufacturer’s recommendations, enclosed with this
8. Care is required when adjusting the gland while manual.
pump is running.
GLAND GUARDS - In the interest of safety of personnel and
COMMISSIONING - All nuts and bolts, securing flanges and in compliance with statutory requirements of various
base mounting fixtures, must be checked for tightness countries, the pumps are fitted with gland-guards that can be
before operation. To eliminate vibration, the pump must be easily removed for adjustment of gland sealing. It is
correctly aligned with the drive unit and the guards must be responsibility of the user to make sure that the guards are
securely fixed in position. All the pipelines must be placed back in position after necessary adjustments have
independently supported and use of expansion joints is been made.
desirable to eliminate the transmission of vibrations and
stresses to the pipelines. When commissioning the plant, all PUMP OPERATING TEMPERATURE - The surface
the joints in the system must be checked thoroughly for temperature range depends upon factors like ambient
leakage. If on starting, the pump does not appear to operate temperature and temperature of the fluid being pumped. If
0
correctly, the pump must be shut down immediately and the the external pump surface temperature goes above 50 C,
cause of the malfunctioning must be established before personnel must be made aware of these and suitable
operations are recommenced. It is recommended that warnings or guarding must be employed.
depending upon plant system operation either a combined
vacuum gauge and pressure gauge, or a vacuum gauge INSPECTION
only, be fitted to the pump inlet port and a pressure gauge ADJUSTMENT OF GLAND PACKING - The gland packing
fitted to the outlet port to continuously monitor the pump should be inspected every day after starting the pump.
operating conditions. It is further recommended that a Remove the gland guards to check the leakage. If the
pressure relief valve of adequate capacity should be sealing is not proper it must be adjusted by tightening or
installed on the discharge side of the pump. loosening of gland nuts to attain the preferred level of
sealing. Excessive tightening should be avoided, as it would
START UP/RUNNING result in excessive heat generation leading to permanent
DRY RUNNING - Pumps must be filled with liquid before damage of both the packing and the drive shaft. Experienced
starting (A threaded plug has been provided on the top of the personnel should carry gland adjustment carefully so that
pump housing for this purpose). The initial filling is not for safety of the personnel is not endangered.
priming purpose, but to provide the necessary lubrication of
the stator until the pump primes itself. When the pump is PERIODIC INSPECTION - To avoid unexpected failure of
stopped, sufficient liquid is normally trapped between the the pump, it is important that the pump is periodically
pumping elements to provide the necessary lubrication for dismantled and routine inspection of the pump is carried out
restarting. If, however, the pump has been left standing for a as follows:
long time or has been dismantled, it must be refilled with Inspection of the pumping elements for wear and tear, after
liquid and given a few turns before starting, to get sufficient every six months or if the discharge falls below acceptable
lubrication between the rotor and stator. levels.
Periodic bearings and universal joints inspection is
If the pumping liquid is hazardous, then extreme care must necessary to maintain optimum performance. The most
be taken while initial filling of the pump using all safety and appropriate time to inspect is during periods of regular
precautionary measures. scheduled downtime for routine maintenance or for any other
reason
NEVER RUN THE PUMP IN A DRY CONDITION EVEN
FOR A FEW REVOLUTIONS OTHERWISE THE STATOR LUBRICATION - The pump should be inspected periodically
WILL BE DAMAGED IMMEDIATELY for lubrication of bearings to see if grease replenishment is
required, and if so, grease should be added in accordance
GLAND PACKING with the instructions given in assembly procedure.
The pump is normally fitted with gland packing, which
required final adjustment during initial running period. Under MAINTENANCE OF WEARING COMPONENTS
normal working conditions the gland rings are to be ROTORS AND STATOR - The wear rate of these
tightened in a manner to permit a slight drip from the gland. components depends on many factors, such as product
This enhances life of the shaft as well as of gland packing. It abrasiveness, speed, pressure etc. One or possibly both
is important to note that the gland packing never be over
 INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS

items will need to be replaced, when the pump performance Whenever Boot seal of EPDM materials are recommended
has reduced to an unacceptable level. or used, please ensure that only the following Silicone
Grease compound is used for such applications.
DRIVE SHAFT – STUFFING BOX - The wear rate under
gland area of the drive shaft depends on various factors like 1. MOLYCOTE 7 COMPOUND
product abrasiveness, extent of tightening of the packing and 2. OKS 1110 GREASE
speed of the pump. Periodic inspection and maintenance of
the gland will maximize the life of the shaft. Replacement of NOTE: The above Greases also comply with food
the gland packing or both the gland packing and the drive applications.
shaft will be necessary when the shaft sealing becomes
difficult to achieve.
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.

PUMPSET - When a pump unit is dismantled and

reassembled, it has to be ensured that the following steps,
as applicable, are covered
1. Correct alignment of pump and driver.
2. Use of appropriate couplings and bushes.
3. Use of appropriate belts and pulleys.

EXPLOSIVE PRODUCTS/ HAZARDOUS ATMOSPHERE -

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.

SPECIAL INSTRUCTIONS

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 or its authorized agents before doing so.

LUBRCATION

Bearings: Pumps should be periodically inspected 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. SHELL Alvaina R3
2. BP Energrease LS#
3. Castro Spheerol AP#
4. Mobilux 3

UNIVERSAL JOINTS

The pin type universal coupling 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. Shell Alvania grease 2

2. Mobilux 2
3. MP Grease 2
4. Castrol Spheerol AP2
 DISMANTLING & ASSEMBLY INSTRUCTIONS
FOR RDCA – 511 / 531 / 551 PUMPS

Before dismantling isolate all electrical circuits. Close all isolation Pump Lantern (1200) and also remove the Tap End
valves on the suction and discharge pipes to the pumps for Stud (41).
prevention of liquid escaping from the pipe work system. The
persons carrying out the work should be adequately trained in Note: -
general workshop practice, relevant to the class of work involved
& aware about safety measures. 1. Clean all the parts and check them for wear / damage.
The worn out / damaged parts should be replaced with
DISMANTLING INSTRUCTIONS: - original ROTO Spares.

2. In order to store dismantled parts use suitable antirust

1. Unscrew the Hex. Nuts (15) fitted to the Tie Rods
compound on the metallic surfaces of component.
(7710) and remove the Spring Washers (16), Punched
Washers (36), Straight Through End Cover (5310), Tie
ASSEMBLY INSTRUCTIONS: -
Rods (7710) and Foot (0760).
1. Tight the Tap End Stud (41) in the Pump Lantern
2. To remove the Bonded Stator (2220) from Pump
(1200) align the Pump Lantern (1200) with Geared
Housing (5010), pour some water or soap solution into
Motor (40) and connect it by tightening the Hex Nut (42)
the Bonded Stator (2220) through the opening in the
after putting the Punched Washer (44) and Spring
Pump Housing (5010) to ease the stiffness. Move out
Washer (42).
the Bonded Stator from the Rotor (2500) by rolling in
the C.W.Direction looking from the drive end.
2. Align the Stub Shaft (4400) with the Geared Motor (40)
at the proper place. Insert the Dowel Pin (2930) in the
3. Unscrew the Hex Nuts (10) and remove Spring
exact place of above fitment by slightly hammering. Fit
Washers (11), Punched Washer (37) and Hex. Head
the Pin Retainer (2850) above the Dowel pin (2930)
Bolts (09), withdraw Pump Housing (5010) taking due
and lock it by Hex. Socket Set Screw (45).
care to avoid any rubbing with the Rotor (2500). Rotor
must be protected by some soft material like cloth.
3. Take the Stuffing Box (5810) and fill the Gland Packing
(7500) in its position and locate the gland (5410) as
4. In order to dismantle the Rotor (2500) from Coupling
shown. Secure the Gland (5410) and Stuffing Box
Rod (2610). UJ (20) has to be dismantled.
(5810) by Studs (07) & Hex Nuts (08). Insert this sub
(Ref. CS-22-009)
assembly over the Stub Shaft (4400) as shown in the
Cross Sectional Drawing.
Remove BSR Retaining Ring (1922), Boot Seal
Retainer (2810), drag out the Boot Seal (1510) & collect
In case of Mechanical Seal, proceed as under:-
the grease. Remove the Spring Pin (01) from the Rotor
(Ref. CS-32-004)
(2500) & Coupling Rod (2610) Head Joint and then
knock out the U.J.Pins (2920) from UJ Head (4010).
Locate Stationary Seal with Seal Ring in the Seal Plate
(5451) in position applying even pressure. In case of
5. Repeat Step 4 to dismantle the Coupling Rod (2610)
Teflon O-ring with Stationary seat, fitment shall be
from Stub Shaft (4400).
made by applying pressure on to the Stationary seat
under a small press or a Drill Machine Spindle, using a
6. Collect Stuffing Box Gasket (8120). Remove the Gland
soft pack on the face of the seat, while driving the
Guards (7620), loosen the Hex Nuts (08) and remove
stationary seat in the Seal Plate (5451).
the Gland (5410) and Gland Packing (7500).
• Fit the Seal Plate with Mechanical Seal
Note: -
Housing (5861) after putting the Gasket
(8190) and locate the assembly on Pump
In case of Mechanical Seal Proceed as under (Refer Lantern (1200). Measure distance ‘L1’ from
CS-32-004), shaft end to face of stationary seat. Now take
out the mechanical seal housing assembly
Unscrew Hex Nuts (32), connecting Seal Plate (5451) with seal plate. If operating length of
and Mechanical Seal Housing (5861), remove mechanical seal is ‘L2’ mark a distance ‘L’
Mechanical Seal Housing (5861) & Seal Plate Gasket on the Stub shaft (4400) equal to ‘L1-L2’
(8190). from UJ end of the Stub Shaft (4400).

Now remove Setscrews from drive collar of Mechanical • Take out the Seal Plate (5451) from the Seal
Seal (30) and take out Mechanical Seal. Remove Seal Housing (5861) by unscrewing the nuts (32).
Plate (5451) along with stationary seat of mechanical
seal. • Slide over the Seal Plate (5451) with
Stationary Seat on to the Stub Shaft (4400)
7. Unscrew the Hex Socket Set Screw (45) from the Pin towards Pump lantern (1200) side.
Retainer (2850) & remove the Pin Retainer (2850)
sliding towards the Head side. Knock out the Dowel Pin • Insert Rotary Part of the Mechanical Seal
(2930). Take out the Stub Shaft (4400). onto the Stub Shaft (4400), taking extreme
care not to damage any part of the seal.
8. Unscrew the Hex Head Nut (42) and collect Spring
Washer (43) & Punched Washer (44). Take out the
 DISMANTLING & ASSEMBLY INSTRUCTIONS
FOR RDCA – 511 / 531 / 551 PUMPS

• Now tighten the Drive Collar of Mechanical Cover (5310) and Pump Housing (5010) keeping the
Seal in place, on the mark at distance ‘L’ over Punched Washers (36), Spring Washers (16) & Hex
the Shaft, with Setscrews. In case Shaft is Nut (15) at the Foot (0760) side. Also insert two Tie
Hard Chrome Plated, tighten the Setscrews Rods (7710) on top side and tight these Tie Rods
on the Shaft after removing plating at places (7710) by Hex Nuts (15), Punched Washers (36) &
to be screwed, by a small hand grinder. Spring Washers (16).

• Now fit Mechanical Seal Housing (5861) 12. Place the Foot (0760) in the position as shown and
between Pump Housing (5010) and Pump Offer the Straight Through End Cover (5310) to Bonded
lantern (1200). Pull Seal Plate (5451) to the Stator (2220).
Seal Housing (5861) and tighten in place with
Studs (31) & Hex Nuts (32). Thread up one Hex Nut (15) and Spring Washers (16)
& Punched Washers (36) each on two Tie Rods (7710)
4. To assemble UJ (20) proceed as under: - as the Foot (0760) has to be using Hex Nuts (15) and
(Ref. CS-22-008) insert the Tie Rods in Straight Through End Cover
(5310) and Pump Housing (5010) keeping the Punched
Clean the internal surface of UJ Head (4010) and place Washers (36), Spring Washers (16) & Hex Nut (15) at
the BSR retaining Ring (1922) and Boot Seal Retainer the Foot (0760) side. Also insert two Tied Rods (7710)
(2810) over the Stub Shaft (4400). Offer the UJ Head on top side and tight these Tie Rods (7710) by Hex
(4010) to Stub shaft (4400) and after alignment of UJ Nuts (15), Punched Washers (36) & Spring Washers
Head and Shaft Holes, insert the UJ Pin (2920) and (16).
finally lock it by Spring Pin (01).
13. After total assembly of the pump, put it on the flat
5. Offer the Coupling Rod (2610) to the UJ Head fitted on surface to check that Foot (0760) are lying & matched
the Stub Shaft (4400). Taking care of alignment of UJ with flat surface and also place the Gland Guards
Head (4010) and Coupling Rod (2610) hole & insert the (7620).
UJ Pin (2920) and lock it by Spring Pin (01).
14. Ensure that all the fasteners except Hex Nuts (08) are
6. Repeat point no. 4,5 for connecting the Coupling Rod tightened properly.
(2610) (2500).

7. Now drag the Boot Seal (1510) in its position taking

care that the left end of it rests on the grooves in the
Stub Shaft (4400). Pour grease inside the joint to fit
complete volume of Universal Joint ensuring that
volume is filled and then locate the right side of Boot
Seal (1510) in the groove provided in the Coupling Rod
(2610).

Now complete the UJ assembly (20) by putting the Boot Seal

Retainers (2810) in it’s place and secured it by BSR
Retaining Ring (1922) at both sides of the UJ (20).

8. Repeat point no. 6,7 for Boot Seal (1510) fitting on

Rotor (2500) & Coupling Rod (2610).

9. Place the Stuffing Box Gasket (8120) at its location and

drag the Pump Housing (5010) without touching the
Rotor (2500) and connect it with Pump Lantern (1200)
by tightening the Hex. Nut (10) after placing the Hex
Head Bolts (09), Punched Washer (37) & Spring
Washer (11).

10. To assemble Bonded Stator (2220), pour some water or

soap solution into the Stator to ease the stiffness. Move
the Bonded Stator (2220) towards the Pump Housing
(5010) by rolling it over the Rotor (2500) in the Anti-
Clockwise Direction looking from the drive end, till butts
with the Pump Housing (5010).
11. Place the Foot (0760) in the position as shown and
Offer the Straight Through End Cover (5310) to Bonded
Stator (2220).

Thread up one Hex Nut (15) and Spring Washer (16) &
Punched Washers (36) each on two Tie Rods (7710) as
the Foot (0760) has to be tightened by using Hex Nuts
(15) and insert these Tie Rods in Straight Through End
 ® ROTO PUMPS MODEL D 551
PERFORMANCE CURVE GRAPH NO. RS-369-02
STARTING TORQUE :- 21.6 Nm. SOLID HANDLING CAPACITY
0
STATOR HARDNESS :- 70 Shore A Soft & Compressible 28 mm
0 Hard & Angular 7 mm.
Tested on Water at 30 c for RA & RR Stator

16

14

0 BAR
12 2 BAR
4 BAR
DISCHARGE (M /hr)

10 6 BAR
3

4
6 BAR
POWER (Kw)

3 4 BAR
2 BAR
2 0 BAR

150
TEMP. ( C)

MARK-V
0

100 MARK- III

50 STD.

0
0 200 400 600 800 1000 1200
SPEED (RPM)
NOTE :- FOR FLUID TEMPERATURE BELOW 100C REFER TO ROTO
TYPE AND FLANGE
DIMENSIONS
SIZE OF
PUMP A1 A2 A3 B1 B2 C1 C2 E1 E2 F1 F2 F3 H1 H2 K L M N ØS1 S2 ØX ØY ØSD RATING ØSS RATING
(BAR) (BAR)
RDCA-492
RDCA-511
RDCA-531
RDCA-551