T E C H N I C A L
D O C U M E N TAT I O N
OPERATING, SAFETY INSTRUCTIONS AND SPARE PARTS MANUAL
GEP.011.01.C01
GEP
GEP11 Gaiotto pump
TRANSLATION
OF THE ORIGINAL INSTRUCTIONS
H
EN
IS
GL
© Copyright
GAIOTTO Automation
The contents of this manual or parts of it must not be copied or given to third parties, unless duly authorized by the editor.
The information contained in this document is reviewed on a regular basis and any corrections will appear in the next editions.
We reserve the right to make technical changes that do not affect operation.
OPERATING, SAFETY INSTRUCTIONS AND SPARE PARTS MANUAL
GEP11 Gaiotto pump
MANUFACTURER
GAIOTTO Automation
Strada Statale 415 Km 27
26010 Vaiano Cremasco (Cremona) - ITALY
PUBLICATION DATE
04.10.2013
REVISION
00
GEP.011.01.C01
1
0
Table of Contents
GENERAL INFORMATION
1-1
1.1 Introduction
1.2 Storing the manual
1.3 How to consult the manual
1.3.1 Safety guidelines
1.4 Users of the manual
1.5 Warranty
1.6 Attachments
1.7 Legend of the safety symbols found in the machine and/or in the manual 1.7.1 Warning signs
1.7.2 Danger signs
1.7.3 Mandatory signs
1.7.4 Additional signs
1.8 Device nameplate
1.9 Declaration of conformity
1.10 Manufacturer's declaration
1.11 General delivery notes
1.12 Notes in compliance with supplement VI of Machine Directive
2
MAIN FEATURES
2.1 Description of the device
2.1.1 General data
2.2 Removing and installing nozzle, stator and pump body
2.3 Removing/installing rotary parts with pin joints 2.4 Removing and installing the supporting system 2.5 Removing and installing the mechanical seal 2.6 Intended, prohibited and misuse of the machine
2.6.1 Intended use
2.6.2 Unintended and prohibited use
2.6.3 Misuse or erroneous use
0-2
1-1
1-1
1-2
1-3
1-4
1-4
1-4
1-5
1-5
1-6
1-7
1-7
1-8
1-9
1-9
1-10
1-10
2-1
2-1
2-2
2-3
2-4
2-6
2-7
2-8
2-8
2-8
2-8
GAIOTTO Automation
Table of Contents
3
0
GEP.011.01.C01
SAFETY DEVICES
3.1 Safety guidelines
3.1.1 General Information
3.2 General safety guidelines
3.3 Residual risks
3.4 Personnel qualification and training
3.5 Risks in the event of noncompliance with safety recommendations
3.6 Safe operation
3.7 Recommendations regarding supervisor/operator safety
3.8 Recommendations regarding safety for maintenance, inspection
and installation jobs 3.9 Transforming and producing spare parts 3.10 Proper and improper use and operating procedures 3.11 Specific recommendations for GAIOTTO pump operation 3.12 Recommendations regarding protection against explosions
3.12.1 Installation and repairs in zones with risks of explosion
3.12.2 Protection against operation without liquids
3.12.3 Safety against overpressure
3.12.4 Motors
3.12.5 Setting the motor 3.12.6 Stabilizing potential in submerged pumps
3.12.7 Stabilizing potential in the other types of pumps 3.12.8 Stator
3.12.9 Joints/lubricating the joints
3.12.10 Check after the first start-up
3.12.11 Shaft supporting system
3.12.12 Materials
3.12.13 Noise emission 3.12.14 Direction of delivery in submerged pumps
3.12.15 Mechanical seals in submerged pumps
3.12.16 Foreign bodies in submerged pumps
3.12.17 Packing
GAIOTTO Automation
3-1
3-1
3-2
3-2
3-3
3-4
3-5
3-5
3-5
3-6
3-6
3-6
3-7
3-8
3-9
3-9
3-9
3-9
3-10
3-10
3-10
3-10
3-10
3-11
3-11
3-11
3-11
3-11
3-11
3-11
3-11
0-3
GEP.011.01.C01
4
0
Table of Contents
INSTALLATION
4-1
4.1 Packing, transport and storage
4.1.1 Storage 4.2 Installation and assembly 4.2.1 Flexible coupler, belt drive 4.2.2 Aligning the pump and the drive unit 4.2.3 Direction of rotation 4.2.4 Pressure 4.2.5 Pipes
4.2.6 Shaft packing 4.2.7 Electric connections 4.3 Electrical connections
4.3.1 Ground connections
5
4-1
4-2
4-3
4-3
4-3
4-3
4-4
4-4
4-5
4-5
4-6
4-6
OPERATING INSTRUCTIONS
5-1
5.1 Commissioning
5.1.1 GAIOTTO pump for food 5.2 Temporary decommissioning
6
5-1
5-2
5-3
MAINTENANCE
6-1
6.1 Routine and special maintenance
6.2 Safety guidelines for maintenance
6.2.1 Setting up the device to perform maintenance under safe conditions
6.2.2 General rules
6.2.3 Hazards and precautions
6.3 Scheduled maintenance
6.3.1 Maintenance procedure
6.3.2 Scheduled maintenance chart
6.3.3 Oil and grease
6.3.4 Cleaning the pump
6.3.5 Lubricating the bearings of the drive shaft 6.3.5.1 Specific grease for bearings
6.3.5.2 Lubricating the shaft bearings 6.3.6 Lubricating the pin joints with SM sealing sleeve
6.3.6.1 Lubricating oil
6.3.7 Shaft with simple effect mechanical seal 6.3.7.1 High sealing requirement 6.4 Troubleshooting and fault removal 6.4.1 Table of problems 6.4.2 How can a cause be found starting from the type of problem? 0-4
6-1
6-1
6-2
6-2
6-2
6-3
6-3
6-3
6-4
6-4
6-5
6-5
6-5
6-6
6-6
6-7
6-9
6-10
6-10
6-10
GAIOTTO Automation
Table of Contents
7
0
DISMANTLING AND DECOMMISSIONING
7.1 Safety
7.1.1 Personnel qualification
7.1.2 Storage conditions
7.2 Decommissioning
7.2.1 Shutdown
7.2.2 Cleaning/Storage
7.3 Recommissioning
7.4 Decommissioning due to dismantling
7.5 Disposal
7.5.1 Introduction
7.5.1.1 Safety
7.5.1.2 Personnel qualification
7.5.2 Disposal
7.6 Units that can be disposed of
7.6.1 Disassembly
7.6.2 Material types
7.6.3 Drop-off centers, agencies
8
SPARE PARTS
8.1 Spare parts
8.1.1 List of recommended spare parts 8.1.2 Type of spare parts 8.2 Spare parts tables
GAIOTTO Automation
GEP.011.01.C01
7-1
7-1
7-1
7-1
7-2
7-2
7-2
7-2
7-3
7-3
7-3
7-3
7-3
7-3
7-4
7-4
7-4
7-4
8-1
8-3
8-3
8-3
8-4
0-5
GEP.011.01.C01
0-6
0
Table of Contents
GAIOTTO Automation
General Information
1
GENERAL INFORMATION
1.1
Introduction
1
GEP.011.01.C01
Before attempting to work on the machine, on the partly-completed
machine and/or packaging of any of the parts, carefully read and become familiar with the entire Instructions Manual. The manual contains
important information for safeguarding the operators that routinely use
and service the machine and for the safety of the machine itself.
Carefully read the SAFETY EQUIPMENT AND PRECAUTIONS
chapter several times as it contains important safety information.
GAIOTTO Automation reserves the right to modify the machine and manual without giving prior notice. Copyright. Reproduction prohibited.
Unauthorized reproduction can result in civil damages and criminal prosecution on the part of
GAIOTTO Automation.
Additional copies of this manual can be obtained from the Customer Service Department at GAIOTTO Automation.
1.2
Storing the manual
The manual is an integral part of the machine and must accompany
it always, even if the machine is sold. The manual must always be
stored near the machine in a location that can be accessed easily by
the operators. The manual must always be at hand so that the operator and maintenance staff is able to rapidly consult it at all times.
GAIOTTO Automation
1-1
GEP.011.01.C01
1.3
1
General Information
How to consult the manual
The information and instructions provided are grouped together and divided into chapters and paragraphs. The user has to simply refer to the table of contents.
The information provided with alert, warning or danger symbols must be carefully read. The notes
pertinent to the operator’s safety or health are given inside a block and are pointed out by alert, warning and/or danger symbols and are written in italics, as shown below.
This warning symbol is used when failure to observe or properly follow the operating instructions, work procedures, etc. may result in
serious personal injury or even death.
This warning symbol is used when failure to observe or properly follow the operating instructions, work procedures, etc. may cause damage to the robot system.
This symbol either underlines general or additional information about
a certain subject or calls the operator’s attention to recommendations
or operations that facilitate the job.
1-2
GAIOTTO Automation
1
General Information
GEP.011.01.C01
1.3.1 Safety guidelines
As regards the mechanical and electrical system of the pump, which is dealt with in the manual provided by the manufacturer, the applicable safety standard has been observed.
If the machine is used for jobs other than those it was designed for,
or used for jobs for which it is not technically suitable, there may be
a risk of:
•
•
•
putting people at risk of injury or death
damaging the pump or other property of the user
compromising the work efficiency of the pump or the operator.
The manual contains numerous warning statements for the applications. GAIOTTO Automation also
provides warnings and safety statements for any accessories and additional equipment supplied.
Before attempting to start work, all persons responsible for installation, parts replacement, adjustments, controlling the robot and performing maintenance and repairs, must carefully read and familiarize themselves with the Instructions manual, above all chapters 3 “SAFETY EQUIPMENT AND
PRECAUTIONS” and 4 “INSTALLATION“, in particular the parts accompanied by the
symbol.
All the texts accompanied by the
symbol are extremely important as they contain shutdown
instructions and other warnings concerning operator safety. These warnings must be carefully followed whenever transporting, installing and operating the plant, making changes and adjustments
and performing maintenance and repairs.
GAIOTTO Automation
1-3
GEP.011.01.C01
1.4
1
General Information
Users of the manual
In this manual the machine operators are categorized as follows:
•
•
Operator-Conductor: responsible for monitoring and operating the machine.
Routine maintenance men.
For more detailed information, see the paragraph dealing with OPERATOR TRAINING in the SAFETY EQUIPMENT AND PRECAUTIONS chapter.
1.5
Warranty
GAIOTTO Automation shall be held responsible only for the machine as it was configured at the
time of delivery. Any operations that alter the configuration or work cycle must be carried out or duly
authorized by GAIOTTO Automation’s Engineering Dept.
GAIOTTO Automation shall not be held responsible for damages deriving from the use of nonoriginal spare parts.
The machine operators and maintenance staff are not responsible
for carrying out operations under warranty, special maintenance and
repairs. These operations are to be performed only by the manufacturers specially trained technicians. For this reason, these types of
operations are not dealt with in this manual.
1.6
Attachments
The complete machine documentation includes other parts provided in the attachments (see the
"Appendix").
If the machine is supplied with additional machines, see the relative manuals for instructions.
1-4
GAIOTTO Automation
General Information
1.7
1
GEP.011.01.C01
Legend of the safety symbols found in the machine and/or in the
manual
Some of the safety symbols listed below are found on the machine and/or in the manual:
1.7.1 Warning signs
General danger or caution!
Risk of electric shock!
Keep away from moving parts!
Do not touch moving chains or conveyors!
Warning! Robot operating
PRIMA DI AVVIARE L’IMPIANTO
VERIFICARE CHE NESSUNA PERSONA SIA RACCHIUSA ALL’INTERNO
DELLA ZONA PERICOLOSA
BEFORE STARTING UP THE PLANT,
MAKE SURE THAT THERE IS NOBODY IN THE DANGER ZONE
GAIOTTO Automation
1-5
GEP.011.01.C01
1
General Information
1.7.2 Danger signs
Do not climb on the machines - Do not go on
board while the machine is running.
Do not repair or adjust while the machines are
operating.
Do not open - Only authorized personnel can open
the cabinet.
Admittance to authorized personnel only.
Do not enter when machine is operating.
ACCESSO CONSENTITO SOLO A
PERSONALE QUALIFICATO PER
OPERAZIONI DI MANUTENZIONE
E FASI DI PROGRAMMAZIONE
ACCESS PERMITTED ONLY
TO QUALIFIED PERSONNEL
FOR MAINTENANCE AND PROGRAMMING PHASES
1-6
GAIOTTO Automation
General Information
1
GEP.011.01.C01
1.7.3 Mandatory signs
Safety gloves must be worn.
Indicated point must be connected to an effective earth-ground.
Carefully read the entire Operation and Maintenance manual.
Keep the safety and protective devices efficient.
1.7.4 Additional signs
Anchoring points.
GAIOTTO Automation
1-7
1
GEP.011.01.C01
1.8
General Information
Device nameplate
FIGURE 1.8 - DEVICE NAMEPLATE
80
GAIOTTO Automation
Strada Statale 415 - Km 27 - 26010 Vaiano Cremasco (CR)
Tel. 0373.279111 - Fax 0373.279299 - http://www.gaiotto.it
POMPA - PUMP
GEP15
Serial no.
50
xxx
Code : E9W000715
35
GAIOTTO
Automation
POMPA - PUMP
SN.
GEP11
30
xxx
Code: E9W0007101
GEP
plates
1-8
GAIOTTO Automation
General Information
1.9
1
GEP.011.01.C01
Declaration of conformity
(Within European Union or when required only)
GAIOTTO Automation declares:
•
that these machines are machines according to the Directive 2006/42/EC and following
amendments and/or supplements and “CE” marking was applied to them;
•
that these machines are machines according to the Directive 2004/108/EC (electromagnetic
compatibility);
•
that the machines are in compliance with the following European Directives (the references to
the rules are to be extended to the subsequent amendments and/or supplements):
•
Machine directive 2006/42/EC
•
Low Voltage Directive 2006/95/EC
•
EMC Directive 2004/108/EC
1.10 Manufacturer's declaration
(Within European Union or when required only)
GAIOTTO Automation declares:
•
that the machines have been manufactured to be incorporated to a machine according to the
Directive 2006/42/EC and following amendments and/or supplements;
•
that the machines cannot be put into operation unless the machines they will be incorporated
to are in compliance with the directions of the Directive 2006/42/EC and following amendments and/or supplements; in particular, the machines cannot be put into operation independently;
•
that the machines are in compliance with the following European Directives (the references to
the rules are to be extended to the subsequent amendments and/or supplements):
•
Machine directive 2006/42/EC
•
Low Voltage Directive 2006/95/EC
•
EMC Directive 2004/108/EC
IMPORTANT!
If GAIOTTO Automation does not supply the entire assembly to which
the machine has to be incorporated, the declaration of conformity of
the assembly is at final user's charge. He also has to interface the
control circuit of the machine described in this manual with the control
circuit of the line to which it will be added, in order to make the assembly compliant with Machine directive requirements.
GAIOTTO Automation
1-9
GEP.011.01.C01
1
General Information
1.11 General delivery notes
Machine parts can be shipped on pallets or packed in crates. Make sure:
•
the package is not damaged;
•
the machine is not damaged (in particular, the frame, the supporting feet, the main switch, the
electrical cabinet and control panel, the control console);
•
the supply corresponds to the order (see delivery note or packing list);
•
In the event of damages or missing parts, immediately inform GAIOTTO Automation, the
shipping agent and his insurance company, sending details and/or photos.
1.12 Notes in compliance with supplement VI of Machine Directive
Follow the conditions indicated below when installing the partly-completed machine so as to ensure
an efficient assembly with other parts and form a complete regular machine that does not compromise safety or health:
WARNING:
The indications given below do not necessarily refer to this partly-completed machine.
if the motor joint or belt are not protected:
IMPORTANT!
Risk of hand injuries or risk of being trapped if the machine operates
and the joint and/or the belt are not protected! Before operating the
machine, protect the motor according to Machine directive 2006/42/
EC!
if the motor was provided for liquid temperatures higher than 80 °C:
IMPORTANT!
Risk of burns if the machine operates and is not protected against contacts and is not provided with covers! Before operating the machine,
protect the motor against contacts or provide covers!
if the motor was provided with heating (stator heating jacket, heating jacket on pump body) exceeding 80 °C:
IMPORTANT!
Risk of burns if the machine operates and is not protected against contacts and is not provided with covers! Before operating the machine,
protect the motor against contacts or provide covers!
1-10
GAIOTTO Automation
General Information
1
GEP.011.01.C01
if the motor is not provided with a monitoring device of the sliding O-ring:
IMPORTANT!
Risk of liquid spills if the sliding O-ring is damaged! Risk of burns in
relation to the type of liquid used! Before starting the machine: - connect the monitoring device of the sliding O-ring! - connect the washing
connection of the sliding O-ring or close it with a screw plug!
if the motor is provided with an open hopper:
IMPORTANT!
Risk of hand injuries or risk of being trapped if the machine operates
and the hopper is not provided with a guard or a protective grid! Before
starting the machine, provide a hopper with guard or with a protective
grid according to standard DIN294 (DIN31001)!
if the motor is provided with a transport device without locking device:
IMPORTANT!
danger caused by motor rolling! Before starting the motor, provide it
with a locking device for the transport device (brakes, securing devices...) and lock to prevent the motor from rolling!
If motors are used as indicated by ATEX:
if the motor is not protected against overpressure:
IMPORTANT!
risk of explosion due to motor overheating! Before operating the machine, protect the motor against overheating!
if the motor is not provided with an anti-drainage device:
IMPORTANT!
risk of explosion due to motor overheating! Before operating the machine, provide the motor with an anti-drainage device! Read the Instructions manual provided for more detailed indications and information regarding pump installation and operation.
GAIOTTO Automation
1-11
GEP.011.01.C01
1-12
1
General Information
GAIOTTO Automation
2
Specifications
2
MAIN FEATURES
2.1
Description of the device
GEP.011.01.C01
The GEP11 GAIOTTO pump is a rotary volumetric pump. The main parts are a rotary part (the “rotor”) and a fixed part (the “stator”). They define the system invented by Professor René Moineau. The
rotor is a screw with round (layout 1/2) or elliptical (layout 2/3) thread, big pitch, high thread and small
diameter of the core. The stator has two or three principles and is twice or 1.5 times the length of the
rotor pitch. In this manner some delivery chambers remain between stator and rotor. They continuously move from the delivery to the exit side when the rotor turns into the stator.
The universal system of GAIOTTO pumps gathers many positive features of other types of pumps.
Like centrifugal pumps, GAIOTTO pumps have no suction and delivery valves but are provided with
an even flow that is proportional to the number of revolutions.
Like plunger pumps, GAIOTTO pumps have a suction capacity up to 8.5 m (vacuometric).
Like diaphragm and peristaltic pumps, GAIOTTO pumps can transfer any type of uneven products,
containing gas and abrasives, also those containing solid and fibrous substances up to a consistency that is no longer runny. Like gear or screw pumps, GAIOTTO pumps can handle very viscous
products.
Like plunger pumps, diaphragm pumps, gear or screw pumps, GAIOTTO pumps can be used for
metering operations. Longitudinal sections and cross-sections of rotor and stator with layout 1/2 during rotor rotation.
FIGURE 2.1 - DESCRIPTION OF THE DEVICE
rotor
posizione
RotorStellung
position
rotore
STATOR
ROTOR
0°/360°
90°
layout 1/2
geometria
1/2
180°
layout 2/3
geometria
2/3
Longitudinal sections
and cross-sections of rotor
and stator with stator wall reduced
270°
LFS001
GAIOTTO Automation
2-1
GEP.011.01.C01
2
Specifications
2.1.1 General data
•
The airborne noise level referred to work environments is ≤70 dB (A).
•
The value was determined when measuring according to standards DIN 45635-24-01-Kl2.
•
Unlike the above standard, the values regarding the drive unit and pipes were not included.
•
The pump should be secured to a cement slab and should not cavitate during rotation
FIGURE 2.1.1 - GENERAL DATA
LFS002
2-2
GAIOTTO Automation
2
Specifications
2.2
GEP.011.01.C01
Removing and installing nozzle, stator and pump body
WARNING!
The pump and the connected pipes must be empty and cool!
•
Detach the connections from the delivery and suction pipes.
•
Remove the hexagonal nuts and the spring washers.
•
Take out the locking plate.
•
Remove the end nozzle from the stator.
WARNING!
when the pumps are provided with hollow rotors:
If the wall is perforated in the zones subject to wear, the pumped product may penetrate the rotor and
flow out when the stator is installed.
Take safety measures if the pumped liquid is dangerous.
•
Take out the stator from the front.
•
Remove the pump body from the bellhousing or from the bearing holding body.
For installation follow the sequence in reverse order.
•
Use glycerine to lubricate when installing the stator on the rotor.
GAIOTTO Automation
2-3
GEP.011.01.C01
2
Specifications
2.3
Removing/installing rotary parts with pin joints
•
Remove both joints as indicated below
to disconnect rotor (1999) from connecting rod (1998):
Removal
•
Push SM sealing sleeve (8235) back
from the side of rotor (1999) and from
the side of drive shaft (1005) or connecting shaft (1050) until the hole of pin
(5075) is uncovered.
•
Remove pin (5075) from rotor (1999),
drive shaft (1005) or connecting shaft
(1050) and take connecting rod (1998)
out of its housing on the side of rotor
(1999) and on the side of connecting
shaft (1050) or drive shaft (1005).
•
Push SM sealing sleeve (8235) towards
the outside part with smaller diameter of
connecting rod (1998) so as to remove
clamping ring (5425) from the grooved
slot of SM sealing sleeve (8235).
•
Take out SM sealing sleeve (8235) and
clamping ring (5425) from connecting
rod (1998), eyebolt side.
1999
1005, 1050
1999
1005
1050
8235
5075
8235
2-4
1998
5425
1998
GAIOTTO Automation
Specifications
2
GEP.011.01.C01
Installation:
•
Insert clamping ring (5425) and SM
sealing sleeve (8235) into the eyebolt of
connecting rod (1998).
•
Push SM sealing sleeve (8235) towards
the outside part with smaller diameter of
connecting rod (1998): place clamping
ring (5425) into its slot on SM sealing
sleeve (8235).
•
Then push SM sealing sleeve (8235)
against the counterplate of connecting
rod (1998).
•
Insert the eyebolt of connecting rod
(1998) into the relevant housing of rotor
(1999) and of drive shaft (1005) or connecting shaft (1050).
•
Assemble rotor (1999), drive shaft
(1005) or connecting shaft (1050) with
connecting rod (1998) by means of pins
(5075). Push SM sealing sleeve (8235)
against the relevant counterplates on
rotor (1999), drive shaft (1005) or connecting shaft (1050).
•
8235
8235
5425
5425
1998
1998
Do the same with the other joint.
1999
1005
1050
1998
5075
8235
GAIOTTO Automation
1998
2-5
GEP.011.01.C01
2.4
2
Specifications
Removing and installing the supporting system
Removal:
•
Remove the spring pin.
•
If the gland (W) housing is secured to the bellhousing, remove only the connecting shaft from
the drive shaft.
•
If the gland (W) housing is separated from the bellhousing, remove it from the bellhousing and
from the drive shaft together with the connecting shaft.
•
When a mechanical seal is provided, proceed as indicated in the relevant paragraph.
Installation:
•
Grease the axial hole of the connecting shaft to prevent rust formation.
•
If the gland (W) housing is secured to the bellhousing, insert the connecting shaft into the
case of the the bellhousing (W) and install on the drive shaft.
•
If the gland (W) housing is separated from the bellhousing, install it in the bellhousing together
with the connecting shaft. At the same time, engage the connecting shaft in the drive shaft.
•
If the pump is provided with mechanical seal, follow the instructions given in the relevant
paragraph.
•
Install the spring pin after it has been greased or oiled.
2-6
GAIOTTO Automation
2
Specifications
2.5
GEP.011.01.C01
Removing and installing the mechanical seal
WARNING!
Cleanliness is very important during these operations. Do not damage
the sealing surfaces and the O-rings. The mechanical seal is removed
from the shaft.
•
Loosen the connecting screws that can be seen and remove the housing body on the shaft.
The housing body may consist of various details in relation to the type of seal. See the attached sectional drawing W...!
•
Remove the separated body parts from the shaft using extreme care. Remove also the items
of the included mechanical seal.
•
Remove the items of the mechanical seal from the body parts with care.
•
Install sealing rings and rings with double teflon covering with care: the connection of the
external covering must be directed towards the assembly direction, otherwise the shell might
open and be detached! For installation follow the sequence in reverse order.
For installation follow the sequence in reverse order.
•
Apply glycerine to the shaft and housing body in the concerned area to avoid friction when
installing the mechanical seal.
WARNING!
Distribute the load evenly when installing the fixed ring by pressing it
or the ring may get damaged. Use a proper pad for big rings. Do not
lay foreign bodies on sealing surfaces.
•
Important: strictly follow the assembly dimensions so that the interface tolerance is properly
closed! (see manufacturer's catalog).
GAIOTTO Automation
2-7
GEP.011.01.C01
2.6
2
Specifications
Intended, prohibited and misuse of the machine
2.6.1 Intended use
The GEP11 GAIOTTO PUMP described in this manual is designed and constructed as part of an
automatic sanitaryware plant. It is used for pumping liquids as described in this documentation and
must work with the supply circuits specified in the project. They must be connected and in a good
supply condition, as determined at the time of machine testing and inspection.
The device is streamlined only for the liquids specified in the technical documentation. Any other
type of liquid and/or material and/or use must be supervised and approved by the Engineering Office
of GAIOTTO Automation S.p.A.
2.6.2 Unintended and prohibited use
The GEP11 GAIOTTO PUMP is designed and constructed to pump liquids determined when developing specifications; therefore use different from that specified by the manufacturer may be hazardous and cause personal injuries and property damage.
No other use is intended. The Manufacturer shall not be held responsible for any personal injury or
property damage arising from failure to heed these guidelines.
2.6.3 Misuse or erroneous use
The manufacturer shall not be held responsible for any personal injury or equipment damage deriving from incorrect and erroneous use of the tool.
Generally speaking, the most common causes of incorrect use are listed below:
•
personnel not adequately trained;
•
fatigue (above all during the night shift) or distraction;
•
negligence caused by superficiality or wrong habits.
Remember that the plant is to be controlled and run exclusively by expert well-trained personnel who
are able to:
•
correctly operate the plant under normal conditions and (extremely important) face any emergencies, overcoming any instinctive reactions and following the correct procedures.
2-8
GAIOTTO Automation
Safety Equipment and Precautions
3
SAFETY DEVICES
3.1
Safety guidelines
3
GEP.011.01.C01
IMPORTANT! Carefully read this chapter.
Installation
Install the machine by following the instructions provided by the Manufacturer and observing the
safety regulations in force in your country. In particular, the machine must be properly connected to
adequate ground electrodes. GAIOTTO Automation shall not be held responsible for any equipment
damage or personal injury resulting from improper installation.
Safety Devices
The machine comes equipped with electrical and/or mechanical safety devices designed to protect
the machine and operator. The safety devices and guards provided must not be removed, altered or
locked out under any circumstances.
GAIOTTO Automation shall not be liable for any equipment damage or personal injury if the machine
operator fails to heed these precautions. If a safety device has been activated, make sure no one is
in the danger zones or hazardous areas before restarting the machine.
Checks, repairs, maintenance
Do not perform any checks, repairs or maintenance operations on moving parts. Clearly visible signs
must be posted to warn all personnel of possible danger.
Before attempting to perform any jobs, shut off the electricity supply with the main switch. The main
switch can be padlocked in the “power off” position to prevent accidental machine start up. To ensure
top machine performance and trouble-free operation, it is essential that the directions supplied by
GAIOTTO Automation are followed and that the required maintenance is carried out.
In particular, check all of the safety devices on a regular basis to verify they work properly and check
the insulation of the electrical cables. Replace the cables, if damaged.
Live parts
It is severely forbidden to work on or near live electrical parts. The electrical cabinet doors must be
kept locked and warning signs signaling potential danger must be placed on them. Before opening
the electrical cabinets or switchboards, shut off the electricity supply with the main switch.
Qualified personnel
The assembling, disassembling and servicing of the machine must be performed by qualified personnel. When carrying out these operations, always use adequate equipment and follow the instructions provided.
Machine no longer used
If the machine is no longer going to be used, make it inoperative by unplugging the power cable from
the mains and applying all the required safety devices.
GAIOTTO Automation
3-1
GEP.011.01.C01
3
Safety Equipment and Precautions
3.1.1 General Information
The smoothing tool, its storage station and its accessories have been designed to reduce the risks
the operator is exposed to but, in any case, all the safety precautions usually taken when operating
mechanical systems must be observed. Before entering the work area and starting operation, the
operator must become familiar with the safety devices provided in the transfer shuttle and its accessories. The latter is designed to be intrinsically safe; in particular, in designing the plant the following
Directives and Harmonized standards were taken into consideration:
•
•
•
Machine directive 2006/42/EC
EMC Directive 2004/108/EC
Low Voltage Directive 2006/95/EC
3.2
General safety guidelines
•
These instructions include basic recommendations to follow during installation, operation and
maintenance. Therefore operators and expert technical staff must read them before installation and start-up and they must be always available in the place where the machine or the
plant are used.
•
Not only the main safety rules indicated in this chapter should be followed but also the special
safety rules given in other main parts, for example those for private use.
3-2
GAIOTTO Automation
Safety Equipment and Precautions
3.3
3
GEP.011.01.C01
Residual risks
The residual risks are listed herein, i.e. remaining potential harm to persons or property that could
not be either totally or reasonably reduced notwithstanding the safety measures employed and listed
above following all possible efforts in design and against which the protective devices are not - or are
not completely - effective.
General personal danger
Danger from voltage
Risk of injuries caused by mechanical parts
Risk connected to overhead loads
Risk for the machine and its operation
Risk for eyes; wear safety glasses.
The indications applied directly on the machine, for ex.
•
- arrow of the direction of rotation
•
- mark for fittings for liquids
must be strictly followed and kept readable.
GAIOTTO Automation
3-3
GEP.011.01.C01
3.4
3
Safety Equipment and Precautions
Personnel qualification and training
The personnel responsible for control, maintenance, inspection and installation must be qualified
for these jobs. The supervisor of the machine must accurately handle responsibility, expertise and
check of the personnel.
Train and inform the personnel if they are not provided with the required knowledge. If required, this
can be done by the manufacturer/supplier on behalf of the supervisor of the machine.
The supervisor must also make sure that the personnel are familiar with these instructions.
•
Transport The supervisor must know how to use lifting devices and slinging procedures in
compliance with the applicable accident prevention rules. Instruct the personnel on the task
to be performed.
•
Assembly to the control unit The supervisor must know the instructions given in training
courses for building mechanic/plant or industrial mechanic.
•
Installation on the plant The supervisor must know the subject of the training course for
plant mechanic.
•
Start-up, operation and maintenance The supervisor must know the construction features
and the operation of the plant to which the pump is added. He should also get informed in
advance on pump operation and know safety indications as well as start-up and maintenance
instructions This knowledge will be put into practice when applicable. Personnel should be
instructed on how to use the pump and the relevant plant.
•
Repairs The supervisor must be familiar with the instructions given in training courses for
building/industrial mechanic. He should provide in advance for details regarding the pump
that are given in the repair instructions. This knowledge will be put into practice when applicable. The auxiliary personnel should be instructed and the repairs made are to be checked.
3-4
GAIOTTO Automation
Safety Equipment and Precautions
3.5
3
GEP.011.01.C01
Risks in the event of noncompliance with safety recommendations
Failure to comply with safety recommendations may involve personal risks as well as risks for the
environment and for the machine.
Failure to comply with safety recommendations may lead to the loss of any right for damage compensation. In particular, noncompliance may involve the following risks:
•
the machine/plant cannot carry out important functions
•
methods indicated for maintenance and repairs will not work
•
personal danger due to electrical, mechanical and chemical effects
•
environmental risk due to leakage of dangerous substances.
3.6
Safe operation
Follow the safety recommendations given in this Instructions manual, the national laws regarding
accident prevention that are in force. Follow also the work, service and safety rules given by the
supervisor.
3.7
Recommendations regarding supervisor/operator safety
If hot or cold machine parts involve risks, the customer must protect them against accidental contact.
Do not remove the cover against accidental contact for moving parts (for ex. joints) when the machine is running.
Leaks (for ex. from shaft seal) of dangerous materials (that are for example explosive, poisonous or
overheated) must be drained so that they are not dangerous for persons and for the environment.
Follow the applicable laws.
The risks connected with electricity are not included (details are given in VDE standards and in rules
of local electric companies).
A GAIOTTO pump is of high quality and operates safely. In particular, when parts made of technical
ceramic are installed in the GAIOTTO pump, like a ceramic rotor, long life is ensured.
However risks may arise in ceramic rotors and in other ceramic parts of the pump when these products are not used according to provisions or in an inappropriate manner.
The operator should check which effects may be connected with a fault of ceramic materials and if
safety measures must be taken to protect the persons and the environment.
We shall not be held responsible for damages arising from faults that are not included in the warranty, indicated in our main sales conditions, and from product specifications that are not ensured in
our order confirmation.
We are liable only in the event of malice or serious negligence.
GAIOTTO Automation
3-5
GEP.011.01.C01
3.8
3
Safety Equipment and Precautions
Recommendations regarding safety for maintenance, inspection
and installation jobs
The supervisor must provide for specially trained, authorized and qualified personnel when maintenance, inspection and installation jobs are to be performed. The personnel should be informed by
reading the service instructions.
NOTE!
As a general rule, work on the machine when it is not running. The
machine should not be under pressure and should be cool. The procedure for machine shutdown indicated in the instructions should be
strictly followed.
Decontaminate the parts or the units that feed devices dangerous for health. Activate the safety and
protective devices after the jobs have been completed.
Follow the indications given in chapter "Start-up" before operation.
3.9
Transforming and producing spare parts
The machine can be transformed and changed only if this was agreed with the manufacturer. Genuine spare parts ad the equipment approved by the manufacturer are useful for safety. The use of
other parts deletes responsibilities for arising damages.
NOTE!
For safe operation, the machine must be constructed in compliance
with the specifications of our manufacturers, using genuine spare
parts and auxiliary devices only.
3.10 Proper and improper use and operating procedures
The machine operates safely only if it is used as indicated in this manual.
This machine was designed based on specific operating data and information given in chapter 2 of
this manual. Information regarding operating conditions is to be considered as an operating limit of
the pump and should be respected.
Pump efficient operation is also connected to proper maintenance, as indicated in chapter 6, and
to proper use of the genuine spare parts indicated in chapter 8 of this manual. Di ricambio e parti
soggette ad usura da altri produttori per l’uso nei nostri prodotti non vengono comunicati, e contrariamente alle istruzioni fornite a voi In questo caso, gli effetti sulla operative e di sicurezza non può
essere dichiarato irricevibile e il funzionamento dei nostri prodotti. Impatto sulla licenza di esercizio
dell’intero sistema della responsabilità civile e sono quindi l’unico responsabile.
3-6
GAIOTTO Automation
Safety Equipment and Precautions
3
GEP.011.01.C01
3.11 Specific recommendations for GAIOTTO pump operation
Use GAIOTTO pumps only in compliance with the purpose for which they were sold.
If the delivery media is changed or replaced, contact the supplier or the manufacturer to see whether
the pump is appropriate also for the new media.
This is valid in particular with aggressive, poisonous or dangerous delivery media. Some of the criteria for pump suitability are:
1. Compatibility of materials and pump parts that come in contact with the delivery media.
2. Construction of seals, in particular shaft seal.
3. Pump strength against pressure and temperature of the delivery media.
Please keep in mind that GAIOTTO pump is a volumetric pump that may generate excessive pressures. If a delivery pipe is obstructed, due to clogging or to an accidental closure of a valve, the pressure generated by the pump may reach a multiple of the allowable pressure of the plant.
As a result, pipes may burst but this is to be avoided, in particular when dangerous liquids are present. The plant should then be provided with suitable safety devices: for ex. pressure switches, safety
disks with return pipes.
Keep in mind the following recommendations when performing maintenance and repair jobs on the
pump:
1. Protect the motor against accidental and improper start-up!
2. Follow the recommendations given for handling the delivery media when opening the
pump! (For ex. safety clothing, no smoking, etc.).
3. Before start-up, make sure that mechanical and other safety devices (covers for chains
and joints) are properly applied.
IMPORTANT!
When working, or performing maintenance or repair jobs, think of your
safety. Therefore, follow the European main directives on machinery,
transformed into national rules, the European standard EN 292, the
specific accident prevention rules, the instructions of the mining authority and follow the applicable technical rules.
GAIOTTO Automation
3-7
3
GEP.011.01.C01
Safety Equipment and Precautions
3.12 Recommendations regarding protection against explosions
When the pumps are used in zones with risks of explosion, always follow the recommendations below to ensure pump protection against explosions over time and avoid the risk of flames.
According to Directive 94/9/CE (ATEX), the pumps can be used in area II 2G IIB T4, II 2G IIB
T3, II 2GD IIB T4 (130 °C) or II 2GD IIB T3 (195 °C).
Consider that the equipment of the drive units installed on the pumps (for ex. gearboxes, joints, )
should comply with DL (Decree-Law) 94/9/EC. Therefore follow the indications given in the documentation regarding the parts assembled.
The scope of use of the machinery is defined by the scope of use of the equipment installed with the
lowest certification and can be different from the one certified for the pump.
Surface maximum
temperature
Temperature class
Maximum temperature
of the feed liquid
T4
130° C
100° C
T3
195° C
165° C
T2
295° C
265° C
T1
445° C
415° C
IMPORTANT!
The declaration of conformity according to Directive ATEX 94/9/EC is
voided if spare parts that were not made or approved by GAIOTTO are
used. Also the manufacturer's warranty referred to the order is voided
because the safety of the operator and/or of the machine is no longer
ensured.
Maximum temperatures are valid for use with mechanical seals made by Burgmann with carbidecarbide and carbide-carbon material solution.
Agree with the manufacturer for other material combinations or for other manufacturers.
3-8
GAIOTTO Automation
Safety Equipment and Precautions
3
GEP.011.01.C01
3.12.1 Installation and repairs in zones with risks of explosion
Pay attention to the risk of flames during installation and repair jobs, in particular when the pump
parts are heated. An example is heating caused by flameproof heating devices or only in areas
where risks of explosions are not present. Check the temperature of the heated parts and the igniting
temperature of the materials subject to the risk of explosion.
3.12.2 Protection against operation without liquids
The pump should never operate without liquids. It should be provided with a proper protective device
against operation without liquids.
The protective device against operation without liquids should be self-controlled: this means that it
can emit an alarm signal and/or it may deactivate the pump also when its control system has failed.
Protection against operation without liquids in fixed submerged pumps (with assembly plate).
Operation is possible only if redundant and self-controlled automatic devices are provided to ensure
protection against operation without liquids and feed flow control.
Protection against operation without liquids in mobile submerged pumps (drum pumps). Filling with
liquid should be ensured during operation following the operating requirements for this purpose:
•
Place and remove drum pumps into/from the container only if they are not active.
•
Prime drum pumps only if they are placed into the container to be drained, when they are
submerged into the liquid.
•
Deactivate drum pumps before they run without liquid, i.e. when this might happen and/or
is going to happen soon based on generated noises (noisy suction or increase in revolution
number).
3.12.3 Safety against overpressure
The maximum allowable pressure should not be exceeded in the pump. The pump should be provided of a safety device against overpressure. The pump cannot direct flows towards a closed gate.
The safety device against overpressure should be self-controlled.
3.12.4 Motors
Motors should be appropriate to the relevant pump delivery. If the pump shuts down, the motors
should turn off independently with the overload cutout.
GAIOTTO Automation
3-9
GEP.011.01.C01
3
Safety Equipment and Precautions
3.12.5 Setting the motor
Set the motor according to the maximum allowable tolerances. Improper setting may damage shaft
seals and bearings.
3.12.6 Stabilizing potential in submerged pumps
Submerged pumps should be included into the stabilization of plant potential. Lay the portable submerged pumps on the ground before placing them into the container.
NOTE!
Interrupt ground connection only when the pump has been completely
removed from the container. No differential potential should be present
between the pump and a container that can conduct electricity.
This means that the container and the pump should be connected to a common ground point and/or
must be connected to each other so as to work as conductors. Portable submerged pumps should
be provided with indications on grounding measures (see grounding).
3.12.7 Stabilizing potential in the other types of pumps
The pump parts that conduct electricity should be included into the stabilization of the pump potential
if the conductive connection to the potential towards the ground is not made safe with drive shaft/
connecting shafts or differently.
3.12.8 Stator
Check the stator wear level at regular intervals.
Replace the stator after the allowable wear level has been reached. Before changing the feed liquid,
the pump's user should ask the manufacturer about stator's strength, unless the stator was already
confirmed for the specified use.
Intervals for stator check and maintenance:
•
for operation > 16 h/day every 6 months at the latest
•
for operation < 16 h/day every year at the latest.
3.12.9 Joints/lubricating the joints
Check the tightness and lubrication of the joints at regular intervals. If required, replace the seals and
lubricate. Intervals for joint check and maintenance:
•
for operation > 16 h/day every 6 months at the latest
•
3-10
for operation < 16 h/day every year at the latest.
GAIOTTO Automation
Safety Equipment and Precautions
3.12.10
3
GEP.011.01.C01
Check after the first start-up
Check the aspects required to ensure protection against explosions (for ex. check lubrication and
wear level) 6 months after the first start-up of the pump at the latest.
3.12.11
Shaft supporting system
Replace the bearings after 14500 hours of operation (in compliance with prEN 13463-5: replace after
90 % of expected useful life has been reached).
3.12.12
Materials
Despite it is allowed, do not use aluminum for pumps in the areas subject to risk of explosions. The
pumps can be used only if materials withstand the mechanical and/or chemical influence and corrosion at the operating conditions to which they are submitted, so as protection against explosions is
not eliminated.
3.12.13
Noise emission
Immediately stop the pump in the event of abnormal noises (for ex. bangs or friction noise). Eliminate
the cause of the failure before starting up. Check the bridge breaker blades at regular intervals.
3.12.14
Direction of delivery in submerged pumps
The direction of delivery in submerged pumps always run from the end fitting to the delivery fitting at
the top. The reverse direction of delivery is not allowed.
3.12.15
Mechanical seals in submerged pumps
Before start-up and after long periods of inactivity, lubricate the mechanical seal from the outside
before inserting the pump. Check the compatibility of lubricant with sealing material.
3.12.16
Foreign bodies in submerged pumps
Make sure foreign bodies cannot penetrate the pump, in particular in portable submerged pumps.
Pumps should be laid on or secured to a clean and stable surface. Stop submerged pumps in the
event of abnormal noise or loss of power.
3.12.17
Packing
Be careful when using shaft packings: packing temperature should not exceed the temperature of
the allowable temperature class. Recommendation: do not overtighten the screws (approx. 5 Nm) of
the packing gland case.
GAIOTTO Automation
3-11
GEP.011.01.C01
3-12
3
Safety Equipment and Precautions
GAIOTTO Automation
4
Installation
4
INSTALLATION
4.1
Packing, transport and storage
GEP.011.01.C01
GAIOTTO pumps are shipped in containers (also for rail transport), unless the customer prefers
something else. Containers are marked and provided with useful indications for handling, according
to standards DIN 55402.
Verify the presence of damages deriving from transport when receiving the goods. Damages deriving from transport should be immediately notified to the shipping agent.
Bring the packed pumps as close as possible to the place of installation and leave them packed as
long as possible.
Lift the pumps with horizontal axis only with the base after they have been unpacked. Use the external fixing holes or the eyebolts on the base. See the drawing with the dimensions.
Lift the pumps with vertical axis using the fixing holes of the bearing plate or eyebolts or the bracket.
The drive unit is usually on top. See the drawing with the dimensions.
WARNING!
Make sure the machines that are heavy on top (with center of gravity higher than the lifting point) do not overturn when lifted. Do not lay
pumps with vertical axis in the vertical position without securing them!
W a r n i n g : t h e y m a y f a l l d o w n ! Place them in the horizontal
position only.
CAUTION!
Do not lift the entire electric pump with the eyebolts of the motor or of
the gearbox. They are to be used for carrying either the motor or the
gearbox.
NOTE!
Strictly follow accident prevention rules in paragraph 18.4 (VBG 9a):
Handling weights with lifting devices. As the structures are very different, only general indications can be given here but usually they are
enough for personnel expert in installation and transport. Contact the
supplier in case of doubt or ask for detailed information regarding your
machine.
If electric pumps with trolleys are handled:
•
Make sure the motor is off and cannot be accidentally started.
•
Move the unit slowly and with care, in particular if the ground is irregular or has slopes. Risk
of overturning!
•
Make sure the position is safe in the new place and lock the wheels/rollers of the retaining
equipment so as to avoid uncontrolled movements.
•
Consider the reaction strength and the torques of bent hoses when the pump is operating.
•
Secure the unit with additional wedges if required.
GAIOTTO Automation
4-1
GEP.011.01.C01
4
Installation
4.1.1 Storage
The pumps are protected during transport, unless otherwise agreed upon. Proceed as follows in
case of prolonged storage before installation:
•
Stator: in the event of a prolonged stop, the rotor can permanently damage the stator on the
contact surfaces (compression-set). Therefore a higher start-up torque is required. Therefore remove the stator and pack it separately. Complete information regarding the storage of
rubber products is given in standard DIN 7716. These recommendations are taken from the
above-mentioned standard and are indicated for a storage time up to 6 months.
As a general rule: Inappropriate storage conditions or inappropriate
treatments change the physical properties of most rubber products.
Their life may be shortened and they can become useless due to excessive hardening, excessive softness, permanent damages, scales,
cuts or other surface damages. These changes may be generated by
oxygen, nitrogen, ozone, heat, light, moisture, solvents or storage under tension. The properties of rubber products do not change over time
(even for a few years) if the products are properly stored and handled.
This does not apply to rubber compounds that are not vulcanized.
Storage place. The storage place should be lukewarm, dry, with little
dust and properly ventilated. An outside storage place with covering
is not acceptable. Do not store rubber products at temperatures lower
than -10°C and higher than +15°C. Do not store them in humid places.
Prevent condensation from being generated. The best conditions are
when relative humidity is below 65%. Products should be protected
from light, in particular from direct sunlight or from a strong light source
with a high percentage of ultraviolet rays. Cover the products to protect them from air changes, in particular from flows of air. As ozone is
highly dangerous, storage places should not include machinery that
releases ozone (like electric motors or other equipment), or generates
sparks or other electric discharges. Do not store solvents, fuels, lubricants and chemical products in the same place.
•
Rotor: lay on wooden blocks and cover to protect it against mechanical damages. RCC rotors
(1.2436): protect the rotor surface against corrosion with grease.
•
Shaft packing: remove the gland, protect shaft and bore with grease.
•
Pump stainless steel parts: protection is not required. ■ Other unpainted parts of the pump:
protect with grease.
•
Drive units: follow the manufacturer's instructions. .
4-2
GAIOTTO Automation
4
Installation
4.2
GEP.011.01.C01
Installation and assembly
If the GAIOTTO pump is stored with a greased rotor: remove the protective grease from the stator,
and clean the rotor to avoid any incompatibilities with the material of the stator and of the product to
be pumped.
Tighten the pump safely in all the securing points (bearing holder body, delivery nozzle, resting feet)
using all the special holes to secure it to the structure underneath (trolley base, foundation block).
4.2.1 Flexible coupler, belt drive
WARNING!
Install the half-joints or the pulleys using the threaded hole on the
shaft. Do not use a hammer!
4.2.2 Aligning the pump and the drive unit
Important section for regular operation
•
Maximum allowable offset for Rotex joints (serially-mounted):
•
•
- radial offset: 1 % (of maximum outside diameter)
- angular offset: 1° 30´
The tolerances indicated in the manufacturer's catalog are valid for other brands installed
upon customer's request.
The pumps complete with base and drive unit are factory-aligned. After securing the base to
the strip of the cement slab, remove the joint cover and check the alignment of the joint with
a ruler. (The base can be damaged if the foundation is not leveled!)
4.2.3 Direction of rotation
The pump direction of rotation is indicated on the plate and on the order confirmation. The direction
of rotation defines the flow direction of the GAIOTTO pump.
NOTE!
Different situations must be agreed upon with the supplier and confirmed by him.
GAIOTTO Automation
4-3
4
GEP.011.01.C01
Installation
4.2.4 Pressure
Unless indicated on the order confirmation, the maximum allowable pressure inside the pump body
(A) (for ex. when the pump turns clockwise) is:
•
gray cast iron pump body: 6 bar
•
welded steel pump body: 10 bar.
The maximum allowable pressure for end nozzle (B) depends on its construction:
•
flange: within rated pressure (for ex. PN 16)
•
female thread: within 25 bar
•
sanitary male thread according to DIN 11851, up to DN 100: within 12 bar for single-stage and
double-stage pumps, within 25 bar for multistage pumps
•
other constructions: within the allowable pressure and, however, within 6 bar/stator stage
installed.
4.2.5 Pipes
•
Place in and out pipes so that liquid is provided after and before the pump when the latter is
stopped. In this manner the quantity of liquid inside the pump is enough to ensure lubrication
at start-up.
•
Provide a pipe section in end nozzle (B) proper for the length ABL (see sketch). The stator can
then be replaced without removing the pump.
FIGURE 4.2.5 - PIPES
B
A
STATOR
ABL
y
DN
z
x
y
x
DN
z
ABL space required for removing the stator expressed in mm
4-4
xxx
GAIOTTO Automation
4
Installation
Pump
dimension
GEP15
GEP.011.01.C01
No. of stages
1
2
90
160
3
230
4
310
6
460
8
610
10
770
12
920
•
Clean and rinse the pipes before connecting the pump.
•
Connect pipes so as to avoid unallowable external loads on pump connections. The installation of expansion joints between the pump and the pipe is recommended:
•
- to avoid having the pipe “rest” on the pump and break the pump body
- to neutralize pump vibrations and prevent them from being transmitted to the
pump body with risk of breakages.
The loads allowed on nozzles (Fx, Fy, Fz) and torques (Mx, My, Mz) comply with standards
API 676 and are indicated in the following chart
Pump type
Standard rated diameter
Fx, Fy, Fz
GEP
DN
[N]
Mx, My, Mz
[Nm]
11
(15) G½”
195
105
15
(32) G1¼”
416
224
Screwed connections should not be
submitted to torques that may loosen
or overtighten the pipe in the pump
body
4.2.6 Shaft packing
If glands with flushing or mechanical seals with connections for “quench”, washing, blocking are
provided, connect with the feed system and adjust before operation. Follow the recommendations.
4.2.7 Electric connections
Specialized and authorized personnel must perform the connected operations following the relevant
provisions (for ex. VDE standards and local provisions of the electric companies).
In particular, as far as control equipment is concerned, follow the most recent release of EEC machine Directive, Appendix I, chapter 1.2 Control equipment.
NOTE!
The original issue of EEC machine directive is knows as directive
89/392/EEC. It was changed a few times after the first release.
GAIOTTO Automation
4-5
GEP.011.01.C01
4.3
4
Installation
Electrical connections
4.3.1 Ground connections
WARNING!
The machine must be connected to an effectively grounded power
point (earth ground). Join the external earth ground to the point marked
PE (EN60445).
PE
Depending on the type of electrical cabinet, the connecting point may
be found:
The connection point is placed on the copper bar on the bottom of the
electric cabinet next to the main switch.
In addition, connect the connection points provided on the device
structure marked with
(417-IEC-5019)
to the external safety circuit.
IMPORTANT!
Failure to ground the indicated parts may cause serious personal injury and damage to the machine.
Any paint present in the device contact points with the earth-ground cables must be removed before
tightening the screws to assure perfect electrical continuity.
Use a suitably sized conductor for ground connections (see the active laws).
4-6
GAIOTTO Automation
Operating instructions
5
5
OPERATING INSTRUCTIONS
5.1
Commissioning
GEP.011.01.C01
Taking into account GAIOTTO pump's structure, follow the indications given below:
WARNING!
A GAIOTTO pump should not be operated without liquid! A few cycles
without liquid may damage the stator!
WARNING!
If GAIOTTO pump was stored with a greased rotor: Before installing
the stator, clean the rotor to avoid any incompatibilities with the material of the stator and of the product to be pumped.
Before starting the pump for the first time, fill it with the liquid to be pumped (for ex. through the screw
plug on the pump body). If the liquid is extremely viscous, first use a runny liquid. This is strictly necessary for the lubrication of the rubber stator. Fill the pump body (only if the pump is to turn counterclockwise) and the pipe on the suction side.
The GAIOTTO pump is a volumetric pump that can theoretically generate an extremely high pressure and either the tank or the delivery pipes might burst.
WARNING!
The rotary parts of the pump that transmit power (shaft, coupling rod,
joints, rotor) would be excessively stressed and might be either partially or fully damaged.
WARNING!
Pressure threshold might be exceeded for body parts and for connecting items that might break down. Pressure strength of body parts is
given in chapter 4 of this Instructions manual.
•
Do not operate the pump against a “closed gate”.
•
Open the gate or the valves before start-up!
•
Run the motor for a short time so as to check the direction of rotation.
GAIOTTO Automation
5-1
GEP.011.01.C01
5
Operating instructions
5.1.1 GAIOTTO pump for food
If a GAIOTTO pump is to be used for food, it should be perfectly clean at start-up. It can be cleaned
in two manners:
A) Disassemble the pump and wash each part by hand with an appropriate detergent. Do not dirty the parts when reinstalling them.
B) Perform a C.I.P. (Cleaning In Place) if the pump shape allows it.
Cleaning is to be performed:
•
before starting the pump for the first time
•
after replacing spare parts that touch the product
•
after operation when a prolonged stop is expected
•
before start-up after a prolonged stop.
Almost all the companies have developed their own CIP systems referred to the products they usually have to pump. In case of doubts, ask your supplier whether the pump is appropriate for the
chosen cleaning system.
CIP typical cycle
•
precleaning with clean water to remove the product from the pump
•
basic cleaning with 1-2 % caustic soda at 60-80 °C for 10-20 minutes
•
intermediate cleaning with clean water for 5-10 minutes
•
acid cleaning with 1-1.5 % nitric acid at 50-70 °C for 5-10 minutes
•
final cleaning with clean water for 5-10 minutes.
During the CIP procedure, the speed of detergent flow should not be lower than 1.5 m/s in every
point.
The stator is submitted to high chemical and thermal stress. For this reason a GAIOTTO pump
should operate with the STOP AND GO system: two or three start-ups limited to one or two rotations
every minute. This operation at intervals is enough for cleaning the chambers between the rotor and
the stator and reduces the additional mechanical stress of the stator submitted to fulling.
5-2
GAIOTTO Automation
Operating instructions
5.2
5
GEP.011.01.C01
Temporary decommissioning
Drain the pump after stopping it and clean it if:
•
the pumped liquid may freeze at ambient temperature, in particular if the pump is installed
outside with harsh climate;
•
the liquid may harden;
•
encrustations may arise on the mechanical seal.
Stator: In case of prolonged stops, the rotor may permanently damage the stator on the contact
surfaces (compression-set). This requires a higher start-up torque. The stator should be removed
from the pump (follow the indications given in chapter 9), pack it to protect it from air and light and
store it in a cool and dry place.
Rotor: Ceramic rotors: remove the ceramic rotors (follow the indications given in chapter 10) and
keep them in a safe place in their original packing. Other rotors: remove the stator, lay the rotor on
some wooden blocks and cover it to avoid any damage. If the rotors are made from RCC (1.2436)
and they are to be used over time, lubricate the surface with grease to avoid corrosion.
WARNING!
Before installing the stator, clean the rotor to avoid any incompatibilities with stator material and with the product to be pumped.
Standby pumps: The standby pumps, that are auxiliary for the main pump, should be operated
from time to time. If not, after a prolonged stop, the pump might be jammed at start-up (reason:
“compression-set”, i.e. permanent deformation of the stator on the surfaces in contact with the rotor).
GAIOTTO Automation
5-3
GEP.011.01.C01
5-4
5
Operating instructions
GAIOTTO Automation
6
Maintenance
6
GEP.011.01.C01
MAINTENANCE
The most common maintenance operations that may be required most frequently are described in
the "Maintenance" chapter of the instructions manual for each machine.
6.1
Routine and special maintenance
Routine maintenance operations are described in this manual.
IMPORTANT!
Contact GAIOTTO Automation Customer Service Department for special maintenance operations that are not described in this manual.
For this purpose, our specially trained personnel hold training courses at our factory in Vaiano
Cremasco. Personnel attending these courses receive all the most important information about machine operation and maintenance and see practical examples of some maintenance jobs.
In any case, our Customer Service Department is at your disposal to aid with any faults, break
downs, routine and special maintenance and anything else regarding the machines and, if expressly
requested, will send a specialized technician to your factory as quickly as possible.
We would like to remind you that the likelihood of faults arising and consequential downtime can
usually be reduced by taking preventive measures. For this purpose, the manufacturer recommends
stipulating a service contract.
IMPORTANT!
Before attempting to perform any maintenance jobs, read and become
familiar with the “SAFETY EQUIPMENT AND PRECAUTIONS” chapter and observe the safety rules and precautions indicated.
6.2
Safety guidelines for maintenance
This chapter contains the safety rules and measures that must be followed when carrying out maintenance operations. In addition, the procedures and any additional safety precautions that must be
followed are specified for each job in this chapter. Before carrying out maintenance operations, make
sure the device is in a safe condition.
Once the maintenance operations have been completed, make sure the device is able to run safely
and, in particular, that the protection and safety devices work correctly. Failure to observe these precautions may cause serious personal injury.
Personnel can carry out only the operations they are responsible for: routine and special maintenance.
GAIOTTO Automation
6-1
GEP.011.01.C01
6
Maintenance
6.2.1 Setting up the device to perform maintenance under safe conditions
Take all the necessary precautions to prevent accidental device start up:
•
shut down the plant which the device is part of;
•
turn the plant’s main switch to position “OFF” (= open);
•
lock the main switch with a pad lock (not supplied) and remove the key; the maintenance
worker working on the device should hold on to the key until the plant is restarted;
•
shut off the air and water circuits and discharge them.
6.2.2 General rules
Good maintenance requires the following:
•
use only original spare parts, tools adequate for the job to be done, keep tools in good condition;
•
carry out the operations at the scheduled intervals, as stated in the manual;
•
pay attention to any trouble signals such as excessive noise, overheating, leaks, etc.
The personnel responsible for maintenance must be well trained and fully know and understand the
standards regarding safety and accident prevention as well as how to employ them.
All unauthorized persons must stay away from the area being worked in while maintenance is under
way. If the safety guards have to be removed, block off the area and put up signs preventing entrance by unauthorized persons.
6.2.3 Hazards and precautions
The safety guidelines given below must be observed along with general accident prevention rules:
•
Never inactivate, alter or lock out the safety devices and guards installed in the device.
•
Do not use toxic or inflammable products to clean or for any other operations.
•
If a part has to be run while maintenance is being carried out to adjust or test it, first make
sure:
- all maintenance personnel is at a safe distance away from the moving parts or danger
zones;
- no tools or material have been left near the moving parts or in areas where they may
be dangerous;
- always use individual protective devices suitable for the job at hand (such as goggles,
masks, heavy duty gloves, safety and slip-proof boots, overalls).
Once the operations have been completed, make sure all the guards
that cover moving parts and drives have been correctly put back in
place and firmly secured.
6-2
GAIOTTO Automation
6
Maintenance
6.3
GEP.011.01.C01
Scheduled maintenance
The routine maintenance operations and intervals at which they are to be carried out to keep the
plant in top working order are given in the table. Performing the scheduled maintenance jobs at the
specified intervals permits faults to be identified before they cause damage.
6.3.1 Maintenance procedure
AL
N
H N IC
T E C N TAT IO
ME
U
C
DO
GET INFORMATION ABOUT MAINTENANCE
The required maintenance operations and intervals at which they
are to be carried out are given in the SCHEDULED MAINTENANCE
chart in this chapter.
OPERATION BEING PERFORMED!
Perform the maintenance job as directed in the Instructions manual
and following all safety rules and precautions.
6.3.2 Scheduled maintenance chart
Job
8
hours
24
hours
350
hours
Lubricating the bearings of the drive shaft
X
Lubricating the pin joints
X
Checking the shaft with mechanical seal
1000
hours
1
year
X
NOTE
The environmental conditions present in the area where the pump is
installed and frequency at which the work cycle is carried out are important factors to be taken into consideration when determining the
frequency at which the checks, repairs and maintenance jobs given
in the chart above need to be performed. It is possible to precisely
schedule when the jobs are to be carried out to intervene more effectively as experience is acquired.
GAIOTTO Automation
6-3
6
GEP.011.01.C01
Maintenance
6.3.3 Oil and grease
Completely replace the oil every 2 years of operation and make sure the greased parts are always
greased. The various types of oil and grease used for the applications are shown in the table that
follows.
Id
Brand
name
Type
Specifications
Application
A
OIL - Spartan EP 320
23°E - 50°C ISO 3498 C320 (320 cSt - 40°C)
General
B
OIL - Spinesso 10
Viscosity 9.8 mm²/s at 40°C ISO 10 - ISO 6743-2
Pneumatic systems
C
GREASE - Beacon 3
D
GREASE - Gr Mu Ep2
Dropping point 180° Penetration 265/295 dmm
Bearings
E
OIL - Blasia S 320
Viscosity 300 mm²/s at 40°C
Gearboxes
F
GREASE - Molyguard C/F
General
High temperatures
As there is a wide variety of lubricants available and there may be differences in the lubricating properties of products that appear identical
but which are manufactured in different areas, the manufacturer shall
not be held responsible for any injury or damage as concerns a lubricant and its specifications.
6.3.4 Cleaning the pump
Wash and/or clean the pump at regular intervals if the delivery media may form deposits (sedimentation).
NOTE!
If the pump is to be opened for this purpose, stop it in advance and
protect the motor against accidental start-up (for ex. loosen the fuse).
Define time intervals between cleanings as they depend on the operating media and type.
The pump can be cleaned:
•
through the cleaning openings provided on the pump body (if any)
•
6-4
in manual mode by disassembling the pump - in automatic mode (CIP) for special pump bodies with cleaning fittings. Information on CIP is given in chapter 5.
GAIOTTO Automation
6
Maintenance
GEP.011.01.C01
6.3.5 Lubricating the bearings of the drive shaft
The rolling bearings of the drive shaft are greased for life at installation.
•
Clean the bearings and fill them with grease whenever they are removed for any reason.
Type of rolling bearings and grease requirement in relation to the outside diameter “d” of the drive
shaft:
Bearing
Ød
in mm
14
Base size
of bearing
holder body no.
GEP15
1
Point A
Type
DIN
3304 B.TVH.C3
628
Point B
Grease for
bearings in no.
grams
4
1
Type
DIN
6303.C3
625
Grease for
bearings in
grams
4
6.3.5.1Specific grease for bearings
Operating temperature
Code DIN 51502
Example
-30...+120
K 3K - 20
“SHELL” Alvania G3
-30...+180
KE 3R - 30
“KLÜBER” PETAMO GHY 443
-36...+280
KFK 3U-30
“KLÜBER” Barrierta L55/3
6.3.5.2Lubricating the shaft bearings
Execution of the pump with “mechanical seal” (cross-sectional view W251.000): Lubricate: at startup every 350 hours of operation before and after operation stops of 6-8 weeks.
GAIOTTO Automation
6-5
6
GEP.011.01.C01
Maintenance
6.3.6 Lubricating the pin joints with SM sealing sleeve
Lubricate the pin joints:
• when worn parts of a joint are replaced
• if the pump is opened for any reason.
Quantity to be used for each pin joint in relation to the outside diameter of joint “D”:
Outside diameter of joint
“D” (see sketch)
Joint base size
type NM
Quantity of oil for each
joint (cm3)
Type N...
25
GEP11
1
28
GEP15
1.5
8235
D
6.3.6.1Lubricating oil
Operating
range
Seal
material
Classification
according to DIN 51502
Approved
product
For food industry
only
FPM
EDPM
CLP
460
FOOD
“KLÜBER” KLÜBERSYNTH UH1 6-460 *)
approved according to USDA H1
Other industries
FPM
NBR
CLP
460
“SHELL” Omala 460
EDPM
CLP HC
460
“KLÜBER” KLÜBERSYNTH UH1 6-460 *)
It is safe for human health only if swallowed in small quantities.
If the leaktight system breaks in joints, up to 450 ml of lubricating oil
might suddenly flow into the pumped product in relation to the size of
the joint, together with metal material coming from abrasions. Therefore check sealing elements of joints at regular intervals and replace
them in time if required. The pin joints can work also without lubricating oil and without the sealing system. The risk of contaminating the
pumped product with lubricating oil is thus avoided. However consider
that the quantity of metal material coming from abrasions due to joint
wear is bigger. This metal material is continuously and forcibly mixed
to the pumped product.
6-6
GAIOTTO Automation
6
Maintenance
GEP.011.01.C01
6.3.7 Shaft with simple effect mechanical seal
The mechanical seals are sold in many different versions. The models standardized according to
DIN 24960 are to be preferred, as their dimensions are the same. For this reason, the replacement
of the type or of the manufacturer does not create any problem.
Mechanical seals may have a forced direction of rotation or they can be reversible.
The seal installed on the pump is described in details in the order confirmation.
The pump provided with a mechanical seal having a forced direction of rotation should never operate
in the direction opposite to the arrow shown on it.
In the event of important leaks, check the surfaces of sliding rings and seals and replace if required.
Simple effect mechanical seals usually work without other auxiliary devices. Their operating range
can be extended if they are completed with a flushing and or "Quench" system.
a) Flushing, in particular with external liquid according to ISO 5199, Annex E, Provision No. 08a or
according to API 610, Appendix D, Outline 32. Especially if liquids are contaminated by solid substances. A clean liquid (1) is poured on the contact area of the sliding surfaces. An additional ring
(2) with small tolerance can be installed. It keeps contaminated pump product (3) away from gland
case (4) if
•
enough washing liquid (1) is injected
•
pressure of washing liquid (1) is higher than pressure of pumped product (3) before the ring.
FIGURE 6.3.7 - SHAFT WITH SIMPLE EFFECT MECHANICAL SEAL
1
atmosfera
atmosphere
prodotto
pumped
pompato
product
3
3
2
4
LMS017
GAIOTTO Automation
6-7
GEP.011.01.C01
6
Maintenance
b) Quench, according to ISO 5199, Annex E, Provisions No. 08, No. 09, No. 10 or No. 13 or according to API 610, Appendix D, Outline 62.
The word “Quench” is used for a system where the sliding surfaces of the mechanical seal (atmosphere side) are kept submerged in an external liquid that is not under pressure.
The "Quench" system is used
• when a simple mechanical seal, without auxiliary devices, does not work (either in part or completely),
• on the other hand, the application of a double mechanical seal with flushing under pressure is not
required because it is useless.
Recommended in the following cases:
• with low temperatures (risk of ice formation)
• vacuum operation (dry friction)
• pumped products that must be isolated from the atmosphere (for ex. due to the formation of sediments or because they are polluted or because of their smell).
The "Quench" liquid absorbs and drains leaks. Sliding surfaces should not work when dry during
vacuum operation.
Pressure should not be present in "Quench" chamber (1) behind the mechanical seal, or the stationary ring would be pushed out of the gland case. Free drainage required in (2)!
The "Quench" chamber can be closed towards the atmosphere in three manners:
1. Low sealing requirement: with small tolerance (4). "Quench" liquid is not permanently present, it
is released only intermittently.
2. Medium sealing requirement: with a seal ring (Simmer) (3). The seal ring should be permanently
lubricated with "Quench" liquid.
FIGURE 6.3.7 - SHAFT WITH SIMPLE EFFECT MECHANICAL SEAL
2
1
3
4
LMS017
6-8
GAIOTTO Automation
6
Maintenance
GEP.011.01.C01
6.3.7.1High sealing requirement
With a second simple mechanical seal (“double mechanical seal, tandem layout”). The external mechanical seal should be permanently lubricated with "Quench" liquid.
Liquid can be fed in two manners in cases 2 and 3 where a permanent “quench” is required:
1. through a pipe provided with a throttle valve and a shutoff valve and a free outlet from the
“quench” chamber of the mechanical seal, as shown;
2. through a storage tank found above the seal at a height not higher than 1 meter, with an outlet
provided with valves on the “quench” chamber of the mechanical seal. The level in the storage
tank must be at sight and may vary from "completely full" to "almost empty". The user should
define the inspection intervals based on his experience.
c) Vertical axis pump with top mechanical seal
IMPORTANT!
when pumps are vertically mounted in relation to top drive unit, for ex.
NT series.
At start-up, the mechanical seal is not in contact yet with the liquid to be pumped and runs shortly
dry, until air has been purged from the pump body.
At the first start-up and after a prolonged stop, lubricate the mechanical seal before starting the
pump.
Lubricate with water, glycerine or oil in relation to the product to be pumped: check the compatibility
with the elastomers of the mechanical seal.
Fill the gap among shaft (1), mechanical seal (2) and gland case (3).
FIGURE 6.3.7 - SHAFT WITH SIMPLE EFFECT MECHANICAL SEAL
1
2
3
LMS017
GAIOTTO Automation
6-9
GEP.011.01.C01
6.4
6
Maintenance
Troubleshooting and fault removal
6.4.1 Table of problems
The table on the next page shows
•
Type
•
possible cause
•
fault removal.
A problem may have different causes:
•
more boxes are checked in the same column
•
A cause may generate various problems: more boxes are checked in the same line
6.4.2 How can a cause be found starting from the type of problem?
•
one or more boxes are checked in the column that refers to a possible problem
•
the possible causes are indicated in the relevant lines, together with useful notes for eliminating the problem (the real cause is defined and identified)
•
if other checked boxes are shown in a line and the relevant problems have arisen, a probable
cause of the problem was identified. The table helps in finding the causes of the problems and to eliminate them when the case is evident.
If this is not possible without ambiguities, contact the manufacturer.
6-10
GAIOTTO Automation
6
Maintenance
GEP.011.01.C01
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Shaft seal is leaking
x
x
x
Rotor duration is limited
Stator duration is limited
Control overloaded
Pump is stopped
x
Pump is noisy
x
Capacity fluctuation
Pressure is too low
x
Capacity is too small
Pump is not sucking
Pump is not starting
Type of problem
x
x
x
x
x
x
x
x
x
x
x
x
GAIOTTO Automation
x
x
x
x
x
Possible cause
How to eliminate the problem
Pump electric data do not
comply with the mains.
Check data on the order. Check the
electric system (two-phase operation).
Pressure is too high.
Measure pressure level with the
pressure gauge and compare it
with the data on the order.
A foreign body is in the pump.
Remove the foreign bodies and
eliminate damages.
The temperature of the
pumped product is too high,
the stator dilates itself excessively.
If the temperature of the delivery
liquid cannot be decreased, use an
undersized rotor.
The stator is bulgy; the elastomer is not resistant to the
pumped product.
Check whether the delivery liquid
complies with the indications on the
order. Replace the stator material if
required.
The solid particles of the
pumped product are too big
and generate obstructions.
Increase the part of floating liquid.
The pumped product leaves
sediments and
hardens.
Clean the pump and wash it after
each delivery has been completed.
Air in suction pipe.
Increase liquid level on suction,
avoid incoming whirpools, avoid air
intake.
The suction pipe is not tight.
Check seals, tighten pipe fittings.
Shaft seal is not leakproof.
Gland: tighten or replace. Sliding
O-ring: replace the gland boxes or
the O-rings, eliminate sediments.
Number of revolutions too low.
With adjustable control: increase
the number of revolutions.
With undersized rotor: operating temperature has not been
reached yet.
Heat the pump (the stator) to the
operating temperature.
Suction height is too high or
feed gate too low (cavitation).
Reduce strength in suction,
decrease the temperature of the
delivery liquid; install the pump in a
lower position.
The pump is operating dry.
Fill the pump; install a device
against dry operation; place pipes
in a different manner.
The stator is worn.
Replace the stator.
6-11
6
GEP.011.01.C01
Maintenance
x
x
x
x
x
x
Rotor duration is limited
Stator duration is limited
How to eliminate the problem
Stator material is fragile.
Install the new stator. Check
whether the delivery liquid complies with the indications on the
order. Replace the stator material if
required.
The rotor is worn.
Replace the rotor; identify the
cause: wear, corrosion, cavitation; choose a different material or
covering.
Joints are damaged.
Replace the parts in question, seal
them and lubricate.
Pump axis is not aligned with
control axis.
Align the motor.
The joint flexible item is worn.
Use a new intermediate item and
align the pump.
Rolling bearings damaged.
Replace the rolling bearings, lubricate and seal them. With high temperatures: pay attention to bearing
tolerance and to lubricant.
Excessive viscosity
Measure viscosity and compare it
with the data on the order.
x
The specific weight of the
pumped product is too high
Measure the specific weight and
compare it with the data on the
order.
x
The gland was not tightened
in an appropriate manner.
Service the gland as indicated
on page 7.4: replace the shaft if
required.
x
The type of packing is not
appropriate for the pumped
product.
Replace the current gland box with
another type.
x
Mechanical seal: wrong direction of rotation
Change the electric connection.
Mechanical seal: sliding ring
and opposite ring are worn.
Lap the rings in question or replace
with new ones.
Mechanical seal: O-rings are
damaged, bulgy or fragile.
Replace the O-rings. Check whether the delivery liquid complies
with the indications on the order.
Change the material if required.
x
x
x
Shaft seal is leaking
Possible cause
Control overloaded
Pump is stopped
Pump is noisy
Capacity fluctuation
Pressure is too low
Capacity is too small
Pump is not sucking
Pump is not starting
Type of problem
x
x
x
x
x
x
x
x
x
x
x
x
x
6-12
GAIOTTO Automation
7
Dismantling
7
DISMANTLING AND DECOMMISSIONING
7.1
Safety
GEP.011.01.C01
Read and understand Chapter 3 ’Safety equipment and precautions’ before performing the described
operations.
IMPORTANT!
Your safety is at stake!
7.1.1 Personnel qualification
Only trained and authorized personnel can intervene on ABT - Rotating base.
7.1.2 Storage conditions
WARNING!
LIQUID SPILL
Polluting liquids may spill out during storage!
Polluting substances must not reach drinking water supply system:
• take appropriate preventive measures
• follow national Safety Data Sheets
• dispose of liquids as special waste, even in small quantities.
Store the product in a place without humidity. Overall dimensions and floor load-bearing capacity are
indicated on the machine layout or on the main layout.
Cover the product to protect it from dirt and dust.
Room temperature has to be included between -10 and +40°C. The product must not be exposed to
excessive temperature changes.
Air humidity must be lower than 75%.
GAIOTTO Automation
7-1
GEP.011.01.C01
7.2
7
Dismantling
Decommissioning
7.2.1 Shutdown
This chapter deals with product stoppage.
WARNING!
FALLING AXES/PIECES
Falling axes/pieces may cause serious injuries or death!
Follow the instructions below:
• Secure overhead axes with the specified devices and lay them to the
ground before working in the dangerous area.
• Do not remain below overhead pieces or axes.
• Make sure the belts of the telescopic axes are not damages or broken.
NOTE:
Do not empty lubrication ducts and gearbox when decommissioning
the product!
Operate as follows for product decommissioning:
1.
2.
3.
4.
Lock the axes.
Shut off the plant (plant main switch).
Disconnect cables ad material supply pipes.
Automatic lubrication (optional): Loosen the greasers and remove the batteries.
Product shutdown has been completed.
7.2.2 Cleaning/Storage
Remove dirt and dust from the product before storage. Carefully clean the product.
NOTE:
Dispose of cloths soaked in oil and grease according to environmental
regulations!
Consult this chapter for information regarding disposal.
Apply anticorrosive coating to all pieces.
7.3
Recommissioning
Recommissioning procedure is similar to commissioning procedure.
Before recommissioning, perform a global inspection as described in chapter 6 ’Maintenance’.
Perform maintenance and repair operations as required.
Perform the following operations after a period of inactivity longer than one year:
•
•
•
•
7-2
Change gearbox oil.
Wash lubrication ducts with new lubricant.
Replace felts and lubricating pinions.
Check the seals and replace if required.
GAIOTTO Automation
7
Dismantling
7.4
GEP.011.01.C01
Decommissioning due to dismantling
GAIOTTO Automation highly recommends re-using any parts that are in good working order such as
motors, gearboxes, fans, etc.
As far as the other parts are concerned, separate the material according to type, for example, iron,
aluminum, plastic, resins, mineral wool, etc.
Collect the oil and any other chemical products and contact firms specialized and authorized to dispose of special waste products.
Carefully follow all specific laws in force in the country where the machine is discarded.
7.5
Disposal
7.5.1 Introduction
Follow the instructions below for disposal:
•
•
•
•
Follow national provisions.
Divide material according to the type.
Dispose of waste according to environmental regulations.
Recycle waste if possible.
7.5.1.1
Safety
Read and understand Chapter 3 ’Safety equipment and precautions’ before performing the described
operations.
IMPORTANT!
Your safety is at stake!
7.5.1.2
Personnel qualification
Only trained and authorized personnel can intervene on Rotmod product.
7.5.2 Disposal
The product consists of the following units:
•
•
•
•
•
•
•
•
•
•
•
•
Package
"Dirty" materials/auxiliary products (oiled paper)
Wood
Plastic (film)
Operational devices
Lubricants (oil/grease)
Batteries
Basic unit
Metals (steel/aluminum)
Plastics (thermoplastics/duroplastics)
"Dirty" materials/auxiliary products (felts/cleaning cloths)
Electric material (cables)
GAIOTTO Automation
7-3
7
GEP.011.01.C01
7.6
Dismantling
Units that can be disposed of
7.6.1 Disassembly
This paragraph deals with product disassembly.
Decommission the product before disassembly as described in paragraph 7.2.1 'Shutdown'.
WARNING!
OVERHEAD LOADS
Improper behavior when overhead loads are present may cause serious injuries, even death!
Follow the instructions below:
• use suitable lifting equipment
• wear the prescribed protective clothing
• keep at safety distance from overhead loads
• do not stand or walk below overhead loads.
WARNING!
OIL/GREASE
Oil and grease pollute!
Oil and grease must not reach drinking water supply system:
• take appropriate preventive measures
• follow national Safety Data Sheets
• dispose of oil and grease as special waste, even in small quantities.
Disassemble the product as follows:
1. Remove the connecting items (cables/cable holder chains)
2. Remove the mobile axes.
3. Remove the gearbox and drain oil.
4. Remove the trolley.
5. Remove fixed parts (axes/supports).
6. Disassemble the parts and separate the materials.
Product disassembly has been completed.
7.6.2 Material types
Dispose of materials according to type as shown in the table below.
Material
"Dirty" materials/auxiliary products
Wood
Plastic
Lubricants
Batteries
Metals
Electric and electronic material
How to dispose of them
Special waste
Common waste
Drop-off center or common waste
Drop-off center
Disposal in compliance with Material Safety Data Sheets
(MSDS)
Battery collection
Metal waste collection
Electrical waste
7.6.3 Drop-off centers, agencies
Drop-off centers and agencies are different for each country. Follow local disposal rules.
7-4
GAIOTTO Automation
8
Spare parts
8
GEP.011.01.C01
SPARE PARTS
INDICAZIONI PER LA RICHIESTA DI PARTI DI RICAMBIO
1.
2.
3.
4.
Rilevare nelle tavole seguenti il numero di figura della parte desiderata.
Su un apposito tabulato, in corrispondenza del numero di figura, si può leggere la denominazione del pezzo, l’eventuale codice di ordinazione e la
quantità effettiva.
Nella pagina seguente é riportato un modulo che può essere fotocopiato e utilizzato a mezzo fax o tramite servizio postale; compilare la richiesta di
parti di ricambio specificando:
- Tipo macchina
- Matricola
- Codice del manuale
- Numero della tavola in cui compare il pezzo desiderato
- Numero di figura
- Codice di ordinazione (se presente)
- Descrizione
- Quantità desiderata del suddetto pezzo
Inviare il modulo, compilato in tutte le sue parti, all’indirizzo sotto riportato.
HOW TO ORDER SPARE PARTS
1.
2.
3.
4.
Refer to the tables below to find the corresponding figure of the required part.
The name of the part, its number and the actual amount are given next to the number of the figure.
A form which can be photocopied and used to order spare parts (via fax or ordinary mail) is provided on the following page. Fill in the spare parts order
form quoting:
- Type of machine
- Serial number
- Manual code
- Number of the table in which the required part is shown.
- Figure number
- Number used to order the part (if given)
- Description
- Number required
Complete the form in its entirety and send it to the address given above.
INDICATIONS POUR COMMANDER LES PIECES DETACHEES
1.
2.
3.
4.
Relever dans les planches suivantes, le numéro de figure de la pièce désirée.
Sur des imprimés appropriés, en proximité du numéro de figure, il est possible de lire la description de la pièces, le code éventuel de commande et la
quantité effective.
Dans la page suivante se trouve un formulaire qui peut être photocopié et utilisé pour fax ou courrier postal. Remplir la demande pour les pièces détachées en spécifiant:
- Modèle de la machine
- Numéro de fabrication
- Code du manuel
- Numéro de la planche où apparaît la pièce désirée
- Numéro de figure
- Code de commande (éventuellement)
- Description
- Quantité désirée
Remplir et envoyer le formulaire a l’adresse indique ci-dessus.
ANGABEN FÜR DIE BESTELLUNG VON ERSATZTEILEN
1.
2.
3.
4-
Die Abbildungsnummer des gewünschten Teils in den folgenden Tafeln suchen.
Auf einer dazu geeigneten Tafel, in Übereinstimmung mit der Abbildungsnummer, ist es móglich, die Bezeichnung des Stücks, die eventuelle Auftrags
nummer sowie die tatsächliche Menge zu lesen.
In der darauffolgenden Seite wird ein Formular angeführt, das photokopiert werden kann und durch Fax oder per Post gesandt werden kann; um die
gewünschten Ersatzteile zu bekommen, folgendes spezifizieren:
- Maschinenmodell
- Seriennummer
- Code des handbuchs
- Nummer der Tafel mit dem gewünschten Stücks.
- Abbildungsnummer
- Auftragsnummer (wenn vorhanden)
- Beschreibung
- Gewünschte Menge
Das ausgefüllte formular an die oben angeführte adresse schicken.
INDICACIONES PARA PEDIR LOS REPUESTOS
1.
2.
3.
4.
Individualizar el número de figura de la pieza deseada en las siguientes tablas:
En un tabulado, al lado del número de la figura, se puede leer la denominación de la pieza, el eventual código de pedido y la cantidad efectiva.
En la página siguiente adjuntamos un módulo el cual puede ser fotocopiado para poderlo enviar mediante fax o correo. Rellenar el módulo especificando:
- Tipo de máquina
- Matrícula
- Código del manual
- Número de la tabla dónde aparece la pieza deseada
- Número de figura
- Código de pedido (si existe)
- Descripción
- Cantidad deseada de dicha pieza
Enviar el módulo, una vez rellenado completamente, a la dirección que está debajo. En la contra-portada indicamos los domicilios de dichas filiales.
INDICAÇOES PARA REQUISIÇAO DE PEÇAS DE SUBSTITUIÇAO
1.
2.
3.
4.
Identificar nas tabela seguintes o núme-ro da peça desejada.
Em um tabulado apropriado, correspon-dente ao numero da figura, pode-se ler a denominação da peça,o código eventual de ordem e a quantidade
efetiva.
Na página seguinte é fornecido un módulo que pode ser fotocopiado e utilizado através de fax ou através de serviço postal. Preencher a requisição
das peças de substituição especificando:
- Tipo de máquina
- Matrícula
- Código do manual
- Número da tabela da peça desejada
- Número da figura
- Código de ordem (se presente)
- Descrição
- Quantidade desejada da peça citada acima
Enviar o módulo completamente preenchido ao endereço indicado.
GAIOTTO Automation - Strada Statale 415 Km 27 - 26010 VAIANO CREMASCO (Cr) - ITALY
Tel. (+39) 0373 279111 - Fax (+39) 0373 279299 - www.gaiotto.it - email: info@gaiotto.it
GAIOTTO Automation
8-1
MODULO PER RICHIESTA DI RICAMBI ORIGINALI
SPARE PARTS ORDER FORM
FORMULAIRE POUR DEMANDE DE PIECES DETACHEES ORIGINALES
FORMULAR ZUR BESTELLUNG VON ORIGINALERSATZTEILEN
MODULO PARA PEDIR REPUESTOS ORIGINALES
MÓDULO PARA REQUISIÇÃO DE PEÇAS ORIGINAIS
GAIOTTO Automation
FAX N°. / FAX NO. / FAX N° / FAX No. / FAX N° / FAX No.
MITTENTE / SENDER / EXPEDITEUR / ABSENDER / REMITENTE / REMETENTE
DATA / DATE / DATE / DATUM / FECHA / DATA
ORDINE N°. / ORDER NO. / ORDRE N° / AUFTRAGSNUMMER / PEDIDO N° / ORDEM N°
MACCHINA / MACHINE / MACHINE / MASCHINE / MAQUINA / MÁQUINA
MATRICOLA / SERIAL NUMBER / N° DE FABRICATION / SERIENNUMMER / MATRICULA / MATRÍCULA
CATALOGO / CATALOGUE / CATALOGUE / KATALOG / CATALOGO/ CATALOGO
TAVOLA
TABLE
TABLE
TAFEL
TABLA
TABELA
FIGURA
FIGURE
FIGURE
ABBILDUNG
FIGURA
FIGURA
CODICE
CODE
CODE
CODE
CODIGO
CÓDIGO
DESCRIZIONE
DESCRIPTION
DESCRIPTION
BESCHREIBUNG
DESCRIPCION
DESCRIÇÃO
NOTE / NOTE / NOTES / HINWEIS / NOTAS / NOTAS
IL RICHIEDENTE / APPLIANT / LE DEMANDEUR / ANTRAGSTELLER / EL SOLICITANTE / O REQUERENTE
PAGINA NUMERO / PAGE NO. / PAGE N° / SEITE NR. / PAGINA N° / PÁGINA N°
QUANTITÀ
QUANTITY
QUANTITE
MENGE
CANTIDAD
QUANTIDADE
Spare parts
8.1
8
GEP.011.01.C01
Spare parts
Parts have to be replaced like for all machinery used in industrial environments. Replacing parts may
also be due to damages deriving from improper operations, accidents or excessive wear. Our AfterSales Service provides a wide range of spare parts.
We supply you with spare parts either when only replacement is required or in case of a routine/
special maintenance schedule. A customized maintenance schedule can be drawn up and our staff
is ready to help you.
Our solutions:
• Assistance for identification of proper spare parts.
• Best quality assurance using only Gaiotto Automation genuine spare parts.
• Supply of recommended lubricants.
• Parts rescue kit.
• Kit of spare parts recommended for your robot.
• Stock pooling.
• Handling spare parts for inspection purposes and reserved spare parts.
8.1.1 List of recommended spare parts
Based on our experience, we are able to help the customer in the best local storage for spare parts.
Our customized solutions often allow a remarkable cost decrease if compared to the standard lists
of recommended spare parts.
8.1.2 Type of spare parts
Based on our experience, we have divided spare parts into three big groups.
•
U - Wear
Mechanically sized material subject to regular wear during plant operation but only the material gets
worn in a reasonably short time (approx. 3 years). The materials that reasonably get worn after 3
years, or better after 5 years, are not be considered materials subject to wear.
• S - Spare
The material that the customer should have in storage when he purchases the plant. These are the
materials that can more easily break down during the first months of the plant and that shut the line
off. They are mostly electric and electronic materials. The basic principle for considering material
SPARE is the operating cycle: "spare" should be extremely critical materials that are average/highly
stressed.
•
F - Optional
Mechanically sized materials with few operating cycles that may get worn but wear process is very
slow and they should not be replaced before 3 years of operation.
GAIOTTO Automation
8-3
8
GEP.011.01.C01
8.2
Spare parts
Spare parts tables
GAIOTTO
Automation
3020
3015
2555
GEP11 GAIOTTO PUMP
GEP.011.01.C01-A
2030
3010
1050
2025
2005
1055
3005
1999
2010
Gaiotto
1998
Automation
0085
0120
0125
0140
Gric1
8-4
GAIOTTO Automation
8
Spare parts
FIGURE
0085
0120
0125
0140
1050
1055
1998
1999
2005
2010
2025
2030
3005
3010
3015
3020
ASSEMBLY
TYPE OF SPARE
PARTS
DATE
F
U
F
F
S
F
F
S
S
F
U
F
S
F
U
S
DESCRIPTION
Bellhousing
Spring washer
Hexagonal head screw
Hexagonal nut
Connecting shaft
Spring pin
Connecting rod
Rotor
End nozzle
Body
Spring washer
Hexagonal nut
Stator
Threaded tie rod
Spring washer
Hexagonal nut
GAIOTTO Automation
RAG.012.OL.C01
TABLE
DESCRIPTION
CODE
M.U.
QUANTITY
NO.
NO.
NO.
NO.
NO.
NO.
NO.
NO.
NO.
NO.
NO.
NO.
NO.
NO.
NO.
NO.
1
4
4
4
1
1
1
1
1
2
2
2
1
2
2
2
8-5
8
GEP.011.01.C01
GAIOTTO
Automation
Spare parts
ROTOR UNIT
GEP11 GAIOTTO PUMP
GEP.011.01.C01-B
8235
1999
5425
5075
1005
1998
1050
Gric2
8-6
GAIOTTO Automation
8
Spare parts
FIGURE
1005
1050
1998
1999
5075
5425
8235
ASSEMBLY
TYPE OF SPARE
PARTS
DATE
S
S
F
S
F
S
S
DESCRIPTION
Drive shaft
Connecting shaft
Connecting rod
Rotor
Cylindrical pin
Clamping ring
SM sealing sleeve for articulation with pin
GAIOTTO Automation
RAG.012.OL.C01
TABLE
DESCRIPTION
CODE
M.U.
QUANTITY
NO.
NO.
NO.
NO.
NO.
NO.
NO.
1
1
1
1
2
2
2
8-7
8
GEP.011.01.C01
GAIOTTO
Automation
Spare parts
SEALS AND RETAINERS
GEP15 GAIOTTO PUMP
7005
GEP.011.01.C01-C
7126
7086
7010
7010
7086
8110
7008
7007
Gric3
8-8
GAIOTTO Automation
8
Spare parts
FIGURE
7005
7007
7008
7010
7186
7126
8110
ASSEMBLY
TYPE OF SPARE
PARTS
DATE
DESCRIPTION
F Gland case for mechanical seal
U Mechanical seal
U Retainer
U Flat washer
GAIOTTO Automation
RAG.012.OL.C01
TABLE
DESCRIPTION
CODE
M.U.
QUANTITY
NO.
NO.
NO.
NO.
NO.
NO.
NO.
1
1
1
1
1
1
1
8-9
GEP.011.01.C01
8
Spare parts
Gric4
8-10
GAIOTTO Automation
Strada Statale 415 Km. 27
26010 VAIANO CREMASCO (CR) - ITALY
Tel. 0373-279111 Fax 0373-27299
www.gaiotto.it