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AERN Series

INDEX
Chapter

Page No.

Introduction

Performance Characteristics

Operation

Shaft Sealing

16

Installation

17

Routine Maintenance Instructions

23

Trouble Shooting

24

Parts List

26

Assembly & Disassembly Instructions

27

10

Dimension Drawing

35

11

Warrantee & Test Certificate

36

Introduction

1.1 General
This instruction manual contains necessary information on the AERN series pumps
having pump model of AERX, AERN & AERB and must be read carefully before
installation, service and maintenance. The manual must be kept easily accessible to the
operator.
Important
The pump must not be used for other purposes than recommended and quoted for
without consulting the company or your local distributor.
Liquids not suitable for the pump can cause damages to the pump unit, with a risk of
personal injury.
1.2 Reception, handling and storage
1.2.1 Reception

Remove all packing materials immediately after delivery. Check the consignment for
damage Immediately on arrival and make sure that the name plate/type designation is in
accordance with the Packing slip and your order.

In case of damage and/or missing parts, report immediately to the carrier at once. Notify
your supplier.

All pumps have the serial number stamped on a name plate.


1

Introduction

1.2.2 Handling

Check the weight of the pump unit. All parts weighing more than 20 kg must be lifted using lifting
slings and suitable lifting devices, e.g. overhead
crane or industrial truck. See section 10 Weights.

Never lift the pump unit with only two fastening


points. Incorrect lift can cause personal injury
and/or damage to the pump unit.

Always use two or more lifting slings. Make sure


they are secured in such away as to prevent them
from slipping. The pump unit should be in a straight
fashion.

Introduction

1.2.3 Storage

After receipt of Material and inspection if the pump is not to be installed


immediately the pump should be re-packed and placed in suitable places.
The following points should be noted:

Cover the pump with corrosion inhibiting treatment material.

Storage location free from, dust, moist and vibration free place.

Rotate the pump unit by hand weekly, to prevent jamming and damaged.
1.3 Safety

The pump must not be used for other purposes than recommended and
quoted for without consulting the company or your local distributor.
Always wear suitable safety clothing when handling the pump.

Anchor the pump properly before start-up to avoid personal injury and/or
damage to the pump unit.
Check to see that the pump can be drained without injuring anyone
and without contaminating the environment or nearby equipment.
3

Introduction

Make sure that all movable parts are properly covered to avoid personal
injury.
All electrical installation work must be carried out by electric personnel.
Improper installation can cause fatal injuries.
Dust, liquids and gases that can cause overheating, short circuits, corrosion
damage and fire must be kept away from motors and other exposed equipment.
If the pump handles liquids hazardous for person or environment, some sort of
container must be installed into which leakage can be led. All (possible) leakage
should be collected to avoid contamination of the environment.
If the surface temperature of the system or parts of the system exceeds 60C,
these areas must be marked with warning text reading "Hot surface" to avoid
burns.

Performance Characteristics

2 Performance Characteristics
2.1 capacity

Drop of capacity with increase in pressure & change of liquid viscosity


2.2 suction pressure
The identification of suction pressure requirement is significant in any pump
application.

Its calculation helps to find out the suction lift of the pump, which enables to
varify whether the pump will be able to self prime or not.

The suction pressure or termed as NPSH ( Net Positive Suction Head ) can be
calculated by following equation
NPSH = Atmospheric pressure + Static Head - Static Lift

ATMOSPHERIC
PRESSURE

STATIC LIFT

STATIC HEAD

Performance Characteristics

2.3 Discharge pressure:

The discharge pressure shown in the delivery line is nothing but the overcoming
of system pressure created by the resistance of the pipeline and the shearing force
of the liquid. Thus it can be said that a gear pump does not develop pressure by its
own but work against the system pressure exerted on it.
2.4 Power Consumption:

1.
2.
3.
4.

The power consumption of a rotary gear pump is mainly influenced by the differential pressure exerted on it.
Factors effecting on power consumption as follows:
liquid viscosity
Sp. gravity of liquid.
Frictional loss.
operating temperature

Performance Characteristics
CAPACITY

THEORITICAL

500 S
SU
200
SS
U

CAPACITY

ACTUAL

IC

SS

20

50

EO

TH

SS

IT

SPEED

HYDRAULIC HP +
VOLUMETRIC LOSSES
FRICTIONAL LOSSES
+
MECHANICAL LOSSES

POWER CONSUPTION
AN NO LOAD
=

OEFFERNTIAL PRESSURE

ACTUAL

20

SS

SS

50

THEORITICAL

SPEED

VOLUME TRIC
LOSSES

ACTUAL
OEFFERNTIAL PRESSURE

POWER CONSUPTION

2.5 Effect of Viscosity:

Viscosity is that property of any liquid which tends to


resist a shearing force.

The change in viscosity very much affects the performance characteristics of the pump i.e. capacity, power
consumption and speed.

At a defined set pressure the capacity of a pump slightly


reduces with decrease in viscosity. This may be due to
increase in internal slippage.

For a pump running at set speed for the desired capacity,


the power consumption increases with increase of liquid
viscosity and decreases with the decrease of viscosity.

The above curves also show the effect of speed with


reference to viscosity.

POWER CONSUPTION

Operation

3.1 Genral
Gears

Pump Casing
Wear Plate

Seal
Drive Shaft

Bearing
R.V. Cover

Front Cover

Relief Valve

Operation

3.2 Operating Principal

Suction

Discharge

Suction

Discharge

Suction

Discharge

The external gear pump uses two identical


gears rotating against each other one gear is
driven by a motor and it in turn drives the other
gear. Each gear is supported by a shaft with
bearings on both sides of the gear.
1.

As the gears come out of mesh, they create


expanding volume on the inlet side of the
pump. Liquid flows into the cavity and is
trapped by the gear teeth as they rotate.

2.

Liquid travels around the interior of the casing


in the pockets between the teeth and the casing
it does not pass between the gears.

3.

Finally, the meshing of the gears forces liquid


through the outlet port under pressure.

Operation

3.3 Safety Relief valve:


3.3.1 Working Principle
The positive displacement principle requires the installation of a safety relief

valve protecting the pump against overpressure.

It can be installed on the pump or in the installation.

This safety relief valve limits the differential pressure (p) between suction and
discharge, not the maximum pressure within the installation.
For example, as media cannot escape when the discharge side of the pump is
obstructed, an over-pressure may cause severe damage to the pump.

The safety relief valve provides an escape path, rerouting the media back to the
suction side when reaching a specified pressure level.

The safety relief valve protects the pump against over-pressure only in one flow
direction.
The safety relief valve will not provide protection against over-pressure when
the pump rotates in the opposite direction.

10

Operation

An open safety relief valve indicates that the installation is not functioning
properly.
When the safety relief valve is not installed on the pump, other protections
against overpressure have to be provided.
If the pump rotates in the opposite direction, the safety relief valve or top
cover must be disassembled and turned around by 180.

Suction

Suction

Discharge

Clockwise Direction

Discharge

Anti Clockwise Direction

11

Operation

3.3.2 Safety Relief valve adjustment:


Adjustment of the standard setting pres
sure is performed at the factory.

To adjust the Safety Relief valve for operating pressure, proceed as follows :
1.
Open the hex cap.
2.
Tighten the ad. screw for increase
set operating pressure or loose the
ad. Screw for reduce the pump operating
pressure.
while increase of operating pressure, power
consumption of pump must not exceed
the motor rated power.
3. Tighten the hex cap. Make sure that air
must leakge from hex cap & ad, screw.

12

Operation

3.4 Check list for starting the pump:


3.4.1 Cleaning the pump

There may be residual mineral oil inside the pump deriving from the pump
testing and the initially lubricating of the bearing bushes.
If the lubricating oil is not acceptable for the pumped liquid, the pump
should be cleaned thoroughly.

3.4.2 Supply and discharge line

Suction and discharge pipes are cleaned.

Suction and discharge pipes are checked for leaks.

Suction pipe is protected to entered foreign bodies.

13

Operation

3.4.3 Characteristics
The characteristics of the pump unit and safety relief valve to be checked.

Pump model see name plate, RPM, working pressure, effective power,
working temperature, direction of rotation, NPSHr etc. as per application

3.4.4 Electrical installation

Electric motor rating as per application data sheet

Electrical installation is complete as per local regulations

Motor voltage corresponds with mains voltage. Check terminal board.

Motor protection is adjusted properly.

Direction of motor rotation corresponds with direction of pump rotation.

14

Operation

3.4.5 Safety relief valve


Safety relief valve (on pump or in piping) is installed

Position of Safety relief valve according to direction of flow.

The set pressure of the safety relief valve is checked.


3.4.6 Drive

Alignment of pump, motor, gearbox etc. is checked


3.4.7 Protection

All guards and safety devices (coupling, rotating parts, excessive temperature)
are placed.

15

Shaft Sealing

4. Shaft Seals:

Differnets type of sealing options are


aviallable as under.
1.
Rubble oil seals
2.
Gland Packing
3.
Mechanical seal

Mech. Seal
4

Mech. Seal Part List

Rubber Oil Seal


& Gland Packing

Stationary Resting Part

spring

O"Ring

Stationary Outer Ring

1
1

Stationary Face

Rotary Face
L-Ring

1
1

16

Installation

5. Installation:
5.1 General:
Pump performance is also dependence on pump installation. This manual gives
basic information which is to be observed during installation of the pump. It is
important to read this manual by responsible person before installation.
5.2 Location & Foundation:

Locate the pump/pump unit as close as possible to the liquid source and if
possible below the liquid supply level. The better the suction conditions, the
better the performance of the pump.

The pump should always be located where it is accessible for inspection, maintenance and repairing.

Every pump should be provide a good foundation by any strong structure to hold
the pump rigid and to absorb any strain or shock that may be encountered. If a
separate foundation is provided, make it at least 4 wider and longer than base
frame.

When the unit is placed on the foundation, it should be leveled and checked
for position against the piping layout and then fastened Owen.
17

Installation

0.200mm

5.3 Alignment:
For running the pump, it is required to couple pump with the drive unit to

get the required speed.

The coupling may be direct drive or belt drive. However direct drive is
preferred over belt drive to reduce load on pump drive shaft and bearings.

During the operation shock load is produce due to pulsation. Therefore,


chose the coupling 1.5 time higher ration than normal constant load.

Pump and drive unit alignment must not more than as shown in fig.

Parralel alignment

18

Installation

5.4 Piping:
Use piping with an equal diameter than the con
nection ports of the pump and shortest possible.

If the fluid to be pumped is high viscous, pressure


losses in the suction and discharge lines may
increase considerably. Other piping components
like valves, elbows, strainers and filters also cause
pressure losses.

Diameters, length of piping and other components


should be selected in such a way that the pump
will operate without causing mechanical damage
to the pump/pump unit, taking into account the
minimum required inlet pressure, the maximum
allowable working pressure and the installed
motor power.

Check the tightness of the pipes after connection.

19

Suction
Strainer

Pump

Isolation valve

Installation

5.4.1 Suction piping


Liquids should enter the pump from a level higher than the pump

level, the inclining pipe should rise upwards towards the pump
without any air pockets.

A too small diameter or a too long suction pipe, a too small or


blocked strainer will increase pressure losses so that the NPSHa
(NPSH available) becomes smaller than the NPSH (NPSH required).
Cavitations will occur, causing noise and vibrations. Mechanical
damage to pump and pump unit is not excluded.

When a suction strainer or filter is installed pressure losses in the


suction line must be checked constantly. Also check if the inlet
pressure at the suction flange of the pump is still sufficiently high.

20

Installation

5.4.2 Isolating valves


To allow proper maintenance it is necessary to be able to isolate the pump.

Isolation can be done by installing valves in suction and discharge lines.

These valves must have a cylindrical passage of the same diameter of the piping.

When operating the pump, the valves must be opened completely. The
output must never be regulated by means of closing valves in suction or
discharge pipes.It must be regulated by changing shaft speed or by re-routing the
media over a by-pass back to the supply tank.
5.4.3 Strainer

Foreign particles can seriously damage the pump. Avoid the entry of these
particles by installing a strainer.

When selecting the strainer attention should be given to the size of the openings
so that pressure losses are minimized. The cross-sectional area of the strainer
must be three times that of the suction pipe.

Install the strainer in such a way that maintenance and cleaning are possible.

Make sure that the pressure drop in the strainer is calculated with the right
viscosity. Heat the strainer if necessary to reduce viscosity and pressure drop.
21

Installation

5.5 Electrical Installation.

Make sure that electrical connection must be properly.

Input voltage & frequency must be match with operating drive motor.

Install electrical overload safety device.

22

Routine Maintenance instructions

6 Routine Maintenance instructions:

Check the nose of pump, Noise must not abnormal.


Temperature of pump body should not exceed the operating temperature.
Check the leakage from suction and delivery line.
Check leakage from gland packing or shaft seal.
Check the air leakage from suction and relief valve.
Check the power consumption.
Check the temperature of the drive unit.
Check the alignment of the pump unit.
Check the axial and radial play of drive shaft

23

Trouble Shooting
Problem

No flow
Under capacity
Irregular discharge
Low discharge pressure
Pump will not prime
Prime lost after starting
Pump stalls when starting
Pump overheats
Motor overheats
Excessive power absorbed
Noise and vibration
Pump element wear
Seizure
Mechanical seal leakage
Packed gland leakage

Probable Causes

Solutions

Incorrect direction of rotation

Reverse motor.

Pump not Primed.

Expel gas from suction line and pumping chamber


and introduce fluid.

Insufficient NPSH available.


(Cavitation)

Increase suction line diameter.


Increase suction head.
Simlify suction line configuration and resuce length.
Reduce pump speed.

Fluid vaporising in suction line.

Increase suction line diameter.


Increase suction head.
Simplify suction line configuration and reduce length.
Reduce pump speed.

Air entering suction line.

Remake pipework joints.


Service fittings.

Strainer or filter blocked.


Fluid viscosity above rated figure.

Increase fluid temperature.


Decrease pump speed.
Check seal face viscosity limitations.

Fluid viscosity below rated figure.

Decrease Fluid temperature.


Increase pump speed.

Fluid temp. above rated figure.

Cool the pump casing.


Reduce fluid temperature.
Check seal face and elastomer temp. limitations.

Fluid temp. below rated figure.

Heat the pump casing.


Increase fluid temperature.

Unexpected solids in fuid.

Clean the system.


Fit strainer to suction line.

Discharge pressure above rated


figure

Check for obstructions i.e. closed valve.


Service system and change to prevent problem recurring.
Simplify dicharge line to decrease pressure.

Gland over-tightened
Gland under-tightened
Pump speed above rated figure.
Pump speed below rated figure.

Slacken and re-adjust gland packing.


adjust gland packing.
Decrease pump speed.
Increase pump speed.

Pump casing strained by


pipework.

Check alignment of pipes.


Fit flexible pipes or expansion fittings.
Support pipework.

Flexible coupling misaligned.


Insecure pump drive mountings.
Shaft bearing wear or failure.
Insufficient gearcase lubrication.
Metal to metal contact of
pumping element.
Worn pumping element.
Relief valve leakage.

Check alignment and adjust mountings accrdingly.


Fit lock washers to slack fasteners and re-tighten.
Refer to pump maker for advice and replacement parts.
Refer to pump maker's instructions.
Check rated and duty presures.
Refer to pump maker.
Fit new components.
Check pressure setting and re-adjust if necessary.
Examine and clean sealing surfaces.
Replace worn parts.
Check for wear on sealing surfaces etc.
Replace if necessary.
Lower pump or raise liquid level.
Use optional materials.

Relief valve chatter


Suction lift too high.
Fluid pumped not compatible
with materials used
No barrier system to prevent
flow passing.

Ensure discharge pipework higher than suction tank.

Pump allowed to run dry.

Ensure system operation prevents this.


Fit single or double flushed mechanical seals.
Fit flushed packed gland.

Faulty motor.
Pumping element missing

Check and replace motor bearings.


Fit pumping element.

24

25

27

28

25

26 2
4

23

22

21

20

19

14

13

11

12

10

15

29
9

16

17

18

8
PARTS
NO.

1
2
3
4
5
6
7
8
9
10
11
12
13
14

DESCRIPTIONS

Parts List
AERN AERX AERB PARTS
PUMP PUMP PUMP NO.

15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

Drain oil plug


Bolt, gland cover
washer, gland cover
Gland cover
Shaft Seal
Bolt, Front cover
Washer, front cover
Dowel
Oil inlet plug
Shaft Bearing
V - seal
Wear Plate
Body Packing
Gears

DESCRIPTIONS
Stator shaft
Rotor shaft
Bearing Sleeve
Snap Ring
Washer, Gear Shaft Assembly
Bolt, Gear Shaft assembly
Pump Casing
R. V. Cover
Hex Cap, Relief Valve
Adjustment screw
R. V. Plug
Spring Sheet
R. V. Spring
R. V. Piston
Front Cover

AERN Pump with Needle Roller bearing as shaft Bearings


AERX Pump with Needle Roller bearing as shaft Bearings & V-seal
AERB Pump with Bush bearing as shaft Bearings
26

AERN AERX AERB


PUMP PUMP PUMP

Assembly & Disassembly Instructions

9.1 General

Insufficient or wrong assembly and disassembly can lead to the pump malfunctioning, high repair costs and long-term inoperability.
Disassembly and assembly may only be carried out by trained personnel. Such
personnel should be familiar with the pump and follow the instructions below.
ANI Engineers is not liable for accidents and damage of the pump or pump unit
for faulty assembly.
Remove the pump from the operation.

9.2 Dissemble Instructions.


9.2.1 Remove gland cover

unscrew hex bolt no.2 & washer

Remove gland cover


2

27

Assembly & Disassembly Instructions

9.2.2 Remove Front cover


unscrew hex bolt no.6 & washer

Open front cover

Remove body packing

Remove dowel if inside the front cover.

Remove V-seal if pump model AERX

Remove shaft bearing (Needle roller or bush )

Remove shaft seal from front cover,no.5

9.2.3 Remove R.V. cover assembly

unscrew hex bolt no.6 & washer

Remove R.V. cover

Remove body packing

Remove dowel if inside the R.V. cover.

Remove V-seal if pump model AERX

Remove shaft bearing (Needle roller or bush )

28

Assembly & Disassembly Instructions

9.2.4 Relief valve disassembly


Open relief valve assembly if

find problem in relief valve


operation.

unscrew hex cap, no.23

unscrew Adjustment screw

Open relief valve plug

Remove spring sheet

Remove spring

Remove piston.
23

29

Assembly & Disassembly Instructions

9.2.5 Remove Gear shaft assembly


Remove wear plates

Remove rotor and stator gear shaft


assembly.

PRESS

9.2.6 Gear shaft disassembly

Unscrew bolts no. 20

Remove washers, no. 19

Remove gears & Bearing Sleeves from


shafts, use the plastic block to avoid shaft
must not damage from press force.

SUPPORT

30

Assembly & Disassembly Instructions


PRESS

9.3 Assembly Instructions.


9.3.1 Gear shaft assembly
Insert Gears in the shafts (one gear is right

hand & second is left hand in pair)

Insert bearing sleeve both side, replace if


damage

Insert washer and screw the bolt no. 20


SUPPORT

9.3.2 Gear shaft assembly

Assembled rotor & stator gear shaft


assembly in pump casing.

Assembled wear plate, replace wear


plates if wear out.

Replace gasket body packing with sealant.


31

Assembly & Disassembly Instructions

9.3.3 Relief valve assembly


Place piston in relief valve cover.

Place spring in piston.

Place spring sheet on spring


Screw the relief valve plug.

Screw the adjustment screw as previously.

Screw the hex cap over the adjustments


screw.
9.3.4 Relief valve cover assembly

Fit the bearing in Relief valve cover.


,replace bearing if damaged

Fit the V-seal in Relief valve cover if pump


model is AERX. (replace the V-seal if
damaged)

Fit the relief valve assembly with pump


casing.

Screw the bolt no. 6 with washer


6

32

Assembly & Disassembly Instructions

9.3.5 Front cover assembly


Fit the bearing in front cover. (replace

bearing if damaged)

Fit the V-seal in front cover if pump


model is AERX. (replace the V-seal if
damaged)

Fit the front cover assembly with pump


casing.

Screw the bolt no. 6 with washer

9.3.6 Pump Rotation Check:

Checks the drive shaft rotates smoothly,


then fit all dowel and tighten the bolt
no. 6.
33

Assembly & Disassembly Instructions

9.3.7 Gland cover Fitting:


Fit the shaft seal in gland cover.

(replace the seal if damaged)

Push the gland cover in to the gland


box.

Screw the bolt no 2. With washer.


(each bolt should b tighten equally)

34

Dimension Drawing

10

Model

OVERALL
DIMENTIONS
H2
A
F

MOUNTING DIMENSIONS
B

H1

FLANGE DIMENSIONS

SHAFT DIMENSIONS

D1 No. OF D2 No. OF P.C.D.


HOLE
SIZE

L1

Weight

Kg.

AE-050-S-M-L 239

150

110

80

100

91

80

69.0

12

08

89

16

60

22

30

11.5

13.0

8.0

AE-100-S-M-L 271

160

130

90

110

100

90

74.0

12

10

108

16

79

25

30

15.0

17.0

14.0

AE-150-S-M-L 318

180

145

105

130

119

100

80.0

14

10

127

16

98

25

40

21.0

23.5

22.5

AE-200-S-L

359

200

165

110

150

133

112

89.5

14

12

152

19

121

40

50

24.0

27.0

28.0

AE-250-S-L

419

220

190

130

160

163

132

100.0

15

15

178

19

140

40

55

27.0

30.0

43.0

AE-300-S-L

461

240

220

160

220

166

160

131.0

20

18

190

19

152

53

60

32.0

10

35.0

59.0

AE-400-S-L

554

280

255

180

270

189

180

145.0

22

18

229

19

190

53

65

37.0

10

40.0

82.0

AE-500-S-L

615

295

280

200

300

215

200

160.0

25

19

254

22

216

60

85

47.0

14

50.5

150.0

AE-600-S-L

690

340

318

220

350

215

225

178.0

26

20

279

22

241

70

95

52.0

16

58.0

175.0

AE-601-S-L

749

360

357

240

380

230

250

200.0

28

22

279

22

241

70

100

57.0

16

61.0

190.0

A
L1
L

H2

H1

D 2

4 Nos D1 Holes

B
35

11

36

Design-Printed : Ketan Pithva 98255 17118