IDROPRES

Pompe
Construction and
Overhaul
Busto Arsizio (VA)

PUMPS “E”-SERIES
OPERATING AND MAINTENANCE
INSTRUCTIONS MANUAL
PAGINA BIANCA
IDROPRES E-series

Pumps “E”-series

operating and instruction manual

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E-series IDROPRES

GENERAL INDEX

 MANUFACTURER AND MACHINE IDENTIFICATION DATA ------------------------------------ 4

 GENERAL SAFETY RULES------------------------------------------------------------------------ 7

SAFETY RULES -------------------------------------------------------------------------------------------------------- 7

ACCIDENT PREVENTION RULES ------------------------------------------------------------------------------------------ 7
 PUMP MAINTENANCE INFORMATION --------------------------------------------------------- 8
USE OF INSTRUCTION MANUAL ------------------------------------------------------------------------------------------ 8
REMARK ------------------------------------------------------------------------------------------------------------------------ 8
MANUFACTURER’S RESPONSIBILITY ------------------------------------------------------------------------------------- 8
REPLACEMENT OF SPARE PARTS ---------------------------------------------------------------------------------------- 8
TECHNICAL ASSISTANCE --------------------------------------------------------------------------------------------------- 8
INTERVENTION REQUEST --------------------------------------------------------------------------------------------------- 9
 GUARANTEE ------------------------------------------------------------------------------------ 9

 PUMP DESCRIPTION AND GENERAL ARRANGEMENT ---------------------------------------- 10

SPECIAL EXECUTIONS -----------------------------------------------------------------------------------------------------11
 TECHNICAL FEATURES------------------------------------------------------------------------- 11

 ALLOWED AND UNALLOWED USE OF THE PUMP --------------------------------------------- 12

 HANDLING AND TRANSPORT ----------------------------------------------------------------- 13

MACHINE LIFTING ----------------------------------------------------------------------------------------------------------13
PUMP WEIGHT ---------------------------------------------------------------------------------------------------------------------------------------- 13

 INSTALLATION --------------------------------------------------------------------------------- 15
INSTALLATION INSTRUCTIONS -------------------------------------------------------------------------------------------15
Pump dimensions ----------------------------------------------------------------------------------------------------------------------------------- 15
PUMP INSTALLATION -------------------------------------------------------------------------------------------------------16
PIPING CONNECTION -----------------------------------------------------------------------------------------------------16
 PUMP DISASSEMBLY AND ASSEMBLY--------------------------------------------------------- 19
DISASSEMBLY-----------------------------------------------------------------------------------------------------------------19
ASSEMBLY ---------------------------------------------------------------------------------------------------------------------20
 PRELIMINARY OPERATIONS BEFORE PUMP STARTING-UP------------------------------------ 21
ALIGNMENT ------------------------------------------------------------------------------------------------------------------21
 PUMP STARTING-UP --------------------------------------------------------------------------- 22
STARTING-UP INSTRUCTIONS --------------------------------------------------------------------------------------------22
START-UP -----------------------------------------------------------------------------------------------------------------------23
 RESIDUAL RISK ANALYSIS --------------------------------------------------------------------- 24
DANGER OF FINGERS -----------------------------------------------------------------------------------------------------24
GENERAL RISKS --------------------------------------------------------------------------------------------------------------24
REMARK ------------------------------------------------------------------------------------------------------------------------------------------------ 25

 MAINTENANCE AND REPAIR ----------------------------------------------------------------- 26

MAINTENANCE INSTRUCTIONS -----------------------------------------------------------------------------------------26
AT THE END OF REPAIR WORKS -----------------------------------------------------------------------------------------26
TROUBLE SEARCH -----------------------------------------------------------------------------------------------------------27

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FUNCTION ANOMALIES --------------------------------------------------------------------------------------------------------------------------- 31

 NOISE------------------------------------------------------------------------------------------ 32

 INSTRUCTIONS FOR FIRES --------------------------------------------------------------------- 32

 INFORMATION FOR OBNOXIOUS SUBSTANCE WASTE DISPOSAL -------------------------- 32

 INFORMATION FOR PUMP DISPOSAL --------------------------------------------------------- 32

 SPARE PARTS ---------------------------------------------------------------------------------- 33

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E-series IDROPRES

MANUFACTURER AND MACHINE IDENTIFICATION DATA

Manufacturer:

IDROPRES S.r.l.
Via DEPRETIS, 23
21052 BUSTO ARSIZIO
(Varese) ITALY

[email protected]

Tel. 0039.0331.681044
Fax 0039.0331.681147

Machine:

PUMP “E”-SERIES

Manufacturing Year

VIA DEPRETIS 23 - BUSTO A. (VA)

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GENERAL SAFETY RULES

For safety’s sake following general rules must be read when operating and maintenance
actions are carried out.

SAFETY RULES

Safety rules involving danger are stated by symbol:

ACCIDENT PREVENTION RULES

The pump, described in this manual, has been manufactured according to “Machinery
Directive 2006/42/EC” and following amendments.

For safety and health of operators, the responsible person must respect and follow the EU
Community Guidelines and the local rules regarding the working environments.

When the machine is operating and when it is under repair, persons not involved in the work ,
cannot stay near the machine.

In any case admittance to production rooms is allowed only to qualified persons.

Should the pump be used with dangerous liquids or at high temperature, approach it with
the due prudence and follow all prescribed safety rules.

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PUMP MAINTENANCE INFORMATION

USE OF INSTRUCTION MANUAL

Before operating the pump, the officers (responsible persons and operators) must be
instructed of “SAFETY RULES” contents, described in this manual.

REMARK

IDROPRES S.r.l. reserves the right to modify the machine due to any construction or
commercial reasons without being compelled to bring the instruction manual up-to-date
immediately.

The pump must be used only for purposes and conditions given at the purchase.
Before changing the application conditions contact our Technicians.
IDROPRES S.r.l. assures the pump only for purposes specified at the purchase, and does not
accept any responsibility for faults or damages caused by a wrong and unsuitable use of the
pump.

MANUFACTURER’S RESPONSIBILITY

The manufacturer takes no responsibility for inconvenient, breaking, accidents, etc. occurred
and caused by the un-knowledge and non-fulfilment of the instructions stated in this manual.
The manufacturer takes no responsibility for modifications, changes and/or installation of
accessories which are not previously authorised.

REPLACEMENT OF SPARE PARTS

Only ORIGINAL SPARES, tested and authorised by the manufacturer, must be used.

TECHNICAL ASSISTANCE

Any maintenance operation, repair, etc. must be carried out by SKILLED PERSONAL or by the
TECHNICAL ASSISTANCE SERVICE

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INTERVENTION REQUEST

For any technical intervention or order of spare parts , you are requested to always indicate
the data stated on the pump’s plate.

Any request must be done after having examined the inconvenient and relating causes
specifying pump type and part number.

Send the request to:

IDROPRES S.r.l.
Via DEPRETIS, 23
21052 BUSTO ARSIZIO
(Varese) ITALY

[email protected]

Tel. 0039.0331.681044
Fax 0039.0331.681147

GUARANTEE

IDROPRES S.r.l. guarantees their products are free of manufacturing defects and all materials
are assured for one (1) year from the date of start-up and however within eighteen (18)
months from the shipping date.
Should the product sold by IDROPRES S.r.l. result to be defective in manufacturing or materials
within the guarantee period under normal operating and maintenance conditions, if
returned to the supplier, the pump will be checked, repaired or replaced free of charges.
IDROPRES S.r.l. will not be responsible for damages due to unproper use by the buyer, his
operators or third persons.
No cost for maintenance or spares on site will be covered by IDROPRES S.r.l. if not authorised
before.
Equipment and accessories purchased from subsuppliers and which are components of
IDROPRES products are guaranteed only if guaranteed by original manufacturers .

THIS IS THE ONLY VALID GUARANTEE APPLICABLE BY IDROPRES S.r.l. AND IT REPLACES ANY OTHER
FORM OF GUARANTEE,

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E-series IDROPRES

STANDARD PUMP DESCRIPTION AND GENERAL ARRANGEMENT

Here under a general description of pumps “E” series. For more details see picture for spare
parts stated on relating chapter.

1 5

4
2

3
6

Picture A

The pump (pict. A) is composed of a pump casing (pos. 1) and a cover (pos. 2) containing all
components suitable for the proper operation of the pump itself.
Inside the pump casing, there is the shaft (pos. 3), rotated by a ball bearing (pos. 4)
assembled on the relating support (pos. 5).
The cover sealing (pos. 2) is assured by gasket (pos. 6).

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SPECIAL VERSIONS (EXAMPLE)

7 8
9

Picture B

For special purposes, the pump can be shaped as stated in pict. B. Outside the pump, you
could see the connections for the flushing or conditioning of seal area (pos. 7), the
connections for vacuum/pressure instruments (pos. 8) and the threaded holes for the
conditioning jacket (pos. 9).

TECHNICAL FEATURES

This instruction book is valid only for standard versions of IDROPRES S.r.l. pumps “E”-series.

All particular constructions and alternatives are not considered in this instructions manual.

For the technical features of the pump you have purchased, consult IDROPRES S.r.l.
catalogue or contact directly our Technical Assistance Service.

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ALLOWED AND UNALLOWED USE OF THE PUMP

The pump must be used only for the process and the type of fluids for which it has been
designed and manufactured.

Utilisation for different processes or types of liquids is strictly forbidden.

The manufacturer declines all responsibilities for unauthorised different utilisation.

Do not exceed the working values specified at the order and/or agreed at the purchase
such as: capacity, rotation speed, pressure and temperature or uses different from those
foreseen in this manual or in the technical documents given by IDROPRES s.r.l. at the
purchase.

The utilisation of the pump under conditions different from those above stated, could bring to
abnormal stresses which the pump could not hold out and can cause damages to persons,
animals or things.

The pump utilisation for other purposes must be authorised by the Manufacturer previously.

IDROPRES S.r.l. assures a safety operating of the pump only if used under conditions specified
at the purchase and does not accept any responsibility for breaking or damages caused by
a wrong and unsuitable use of the pump.

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HANDLING AND TRANSPORT

WARNING

TRANSPORT, UNLOADING AND LIFTING OF THE MACHINE must be carried out

by skilled and authorised persons only.

MACHINE LIFTING

PUMP WEIGHT
MIN 20 Kg. MAX. 900 Kg.
To know the exact weight of the pump you have purchased,
contact the manufacturer IDROPRES S.r.l.

Sling the pump as stated in the pictures below (with or without motor) and check the belts
are well fixed before lifting it.
Be careful the pump is well balanced during its lifting.

Handle the pump carefully.

Picture C

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Picture D
WARNING

VERIFY THAT ALL EQUIPMENT DOES NOT SWING TOO MUCH

DURING THE LIFTING. IN THIS CASE STOP THE LIFTING
IMMEDIATELY AND WAIT FOR THE ROCKING END BEFORE
PROCEEDING WITH LIFTING OPERATIONS.

TAKE ALL UNINVOLVED PERSONS AWAY.

Picture E

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INSTALLATION

INSTALLATION INSTRUCTIONS

All operations must be carried out by authorised or qualified persons. Carry out the work
observing following rules:

 Any pressure inside the chamber must be discharged through the suction or discharging
conducts or other suitable connections.

 The transmission gears must be locked or rendered inoperative, so that they cannot start
during operations on the pump.

 The pumps in touch with dangerous substances have to be decontaminated and made
safe.

 Changes or modifications of the products are allowed if approved and authorised by

IDROPRES S.r.l. All modifications or installation of spares not authorised are out of IDROPRES
S.r.l. responsibility.

ATTENTION:

During the installation and tests, the pump must be protected against accidental
movements.

Necessary spaces for work and maintenance operations must be kept free around the pump.

Pump dimensions

This manual is valid only for pumps “E”-series manufactured by IDROPRES S.r.l.

Particular construction types and alternatives are not considered in these instructions.

For the dimensions of the pump you have purchased, consult IDROPRES S.r.l. catalogue or
contact our Technical Assistance Service.

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PUMP INSTALLATION

The pump can be connected directly to the piping. An horizontal position of the pump is
suggested for better operation conditions. However, for particular conditions, the pump can
be fitted vertically.

Place the pump close to the fluid to be pumped, and, if possible, fit it under the fluid level.
Pumps “E”-series are selfpriming but better are the suction conditions, far better will be the
pump performances.

The pump must be fitted with easy access for maintenance and inspection. A suitable space
must be foreseen for the removal of big pumps.

The sense of rotation determines the suction and delivery connections. To establish the sense
of rotation, it is always necessary to look for the end part of the pump shaft. If otherwise
stated, the rotation is clockwise, that is with suction connection placed on the right side of
the pump. The idle pin, which results to be decentralised on the pump cover, should be
placed towards the outlets and at the same distance.

After the complete fitting of the pump and connection of piping, check the alignment again.

An over-pressure valve must be always foreseen for the pump discharging end.

PIPING CONNECTION

The pipes must be anchored close to the pump and connected to the same without
transmitting any stress. Their weight must not load on the pump.
According to the plant type and relating pumps, we suggest to install emergency stop
devices and interception valves. Piping expansions due to heating effect must be suitably
compensated in order to avoid stresses on the pump.
However before starting new plants, remind to clean, wash and blow tank, piping and fittings.

Unsuitable suction piping type can cause many pumping problems. The pumping plant
should be large and short as much as possible.

Before fitting and installing the piping system, take following points in due consideration:

1. Do not use piping smaller than the orifices of the pump connection.

2. Clean the inside part of the piping before the connection.

3. NON RETURN VALVE - When you pump a light fluid with a negative suction, a non-return
valve placed at the end of discharge piping or a check valve installed in the first horizontal
stretch, will facilitate the pump priming. Be sure that the check valve is quite big in order to
avoid excessive load losses.

4. When you approach an obstacle with the suction or discharge piping, turn around the
obstacle instead of passing over, avoiding possible shaping of air-pockets (see pictures of the
next page)

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5. Where possible, place piping inclined in order

to avoid possible shaping of air or fluid pockets.
Air-pockets inside piping make the pump
operation difficult.

6. In case of a discharge piping with long

horizontal stretch, keep the horizontal portion
below the fluid level if possible. In such a way the
piping will be full and the pump has not to move
a big quantity of fluid at start-up. This is
particularly useful when a check valve is not
fitted.

7. When you fit an hot or cold system (the

managed fluid has a temperature which is
different from the air around the pump) be sure Picture F
that the piping has the possibility to expand or
shrink.
Expansion unions (with support) or supported
floating piping should be used so that the pump
body cannot be distorted or bent.

8. NET FILTER - It is a good rule to foresee a net

filter on the suction side of the pump to prevent
entry of foreign matters into the pump which
could damage it or the motor. The filter net or the
hole section must be quite large to avoid
excessive pressure drops and, at the same time, quite small to protect the pump. In case you
have doubts about the pump dimensions, contact the manufacturer and give him the piping
dimensions, the delivery and viscosity as well.
The use of a filter is very important for the
first start-up of the system in order to
keep it cleaned from welding residuals,
incrustations or other foreign matters.

9. If an overpressure valve is not

provided on the pump, the fitting of it on
the discharge piping is recommended.

10. The pump must not be used to bear piping,

the piping weight should be supported by
hooks, brackets etc.
When you fit the piping to the pump, do
not apply stress on the pump body.
Springing or pulling pipes towards the
pump may cause distortions, possible
misalignments and probable quick wear
of the pump.
Do not use the pump to correct errors of
pipe laying or assembly.

11. All pipe couplings must be locked. A pipe

mastic or a Teflon tape can be used to avoid
any loss. Losses in the suction piping allowing
air suction can cause noise, capacity
Picture G reduction and damages to the pump.

10. Check again the transmission alignment after the pipes are coupled.

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E-series IDROPRES

12. The auxiliary piping connected to jackets for cooling/heating or other necessities, must be
installed with the same care reserved to the pipes for fluid pumping.

13. An overpressure device is to be foreseen for each side of the pump or the piping system,
protected by interception valves, and, therefore, completely insulated.

14. Interception valves on both delivery and suction way must be provided in order to allow the
maintenance operations or replacement of the pump without causing excessive losses of the
product.

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STANDARD PUMP DISASSEMBLY AND ASSEMBLY

The assembly and disassembly operations must be carried out only by specialized and
authorized technicians.
Before carrying out these operations on the pump, please verify:

1. The pressure inside the chambers must be completely discharged through the suction/drain
lines.

2. Switch off the tension of the electric plant connected to the pump and verify that all
transmission gears are locked to avoid they could be started when working on the pump.

3. Pumps used to manage dangerous substances for the operator must be decontaminated.

DISASSEMBLY

ATTENTION
Mark all components before disassembly them to assure a correct reassembly of the pump.

1. Remove the seeger ring and the spacers on the shaft (if present) and the screws of the
bearing box (pos. 3) and extract it by means of a puller. Clean the shaft (pos. 6) and remove
any product mark and eventual dinges. This is very important to avoid damages to the
packing elements and shaft bushing during the disassembly phase. Unscrew the setscrew
and remove the packing gland (pos. 18).

2. Unscrew and remove the cover (pos. 2) and the idler gear (pos. 5) using the suitable
extraction holes; pay attention to avoid idler gear could fall.

2.1. If the pin (pos. 7) needs to be replaced, it has to be removed heating it at 150°C to burn
the LOCTITE adhesive used for the first assembly.
Insert the new pin, after a careful clean of the parts, gluing it with LOCTITE 696;
Refer to the picture I, for the correct pin positioning.

3. Beat gently on the shaft, drive side, with a plastic hammer, for the extraction of the shaft
pos. 6 complete with drive gear (pos. 4).

4. Check the idler gear bushing (pos. 9) and the shaft bushing (pos. 8); If the radial play value
is not included between 0,05-0,08 mm, it is necessary to replace it.
Check also the wear of the shaft (pos. 6). If it shows signs of wear, it has to be replaced.

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E-series IDROPRES

Picture H
ASSEMBLY

1. Insert the wheel and the shaft into the body pos. 6-4, fit the cover pos. 2 without the gasket
pos. 11 and idler gear pos. 5. Beat delicately with a pipe on the shaft bushing pos. 8 in order
to eliminate the axial play between drive gear and cover. With a drill make a countersink on
the shaft bushing inside the setscrew hole, clean the hole carefully and insert the setscrew
without tightening too much, using an hermetic product on the thread (type LOCTITE 542).

2. Remove the cover. Before fitting the cover, it is necessary to measure the depth between
the drive gear and the pump body (quote A of the drawing below) and verify it is the same
to 0,2 mm less than quote B (cover depth). Use gaskets to reach the operating tolerances.
Insert the idler gear and the gasket pos. 11 of thickness from 0,2 to 0,5 mm, according to the
viscosity of the pumped product. Insert the seeger ring and the spacers on the shaft (if
foreseen); Lubricate and reassemble.

PUMP BODY
-0.3

DRIVE GEAR

PUMP COVER

B A
Picture I
3. Insert the gland rings alternating the joints. Then fit the packing nut and the bearing block.

“IDROPRES S.R.L.” technical service is at your complete disposal for any further info.

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PRELIMINARY OPERATIONS BEFORE PUMP STARTING-UP

Before pump starting-up, following controls must be carried out in order to avoid any
damage.

 First of all verify that the pump is not damaged during transport and lifting.
 For any doubts about integrity of the pump, equipment and accessories, contact the
manufacturer (see “PLANT MAINTENANCE ASSISTANCE INFORMATION”)
 Remove the blocking elements put by the carrier in the movable parts
 If the pump remains unused for long time and may be subject to atmospheric agents,
remove any possible corrosion with suitable detergent substances (effect disassembly and
cleaning).

CAUTION:

These substances can be harmful if used improperly, skin-absorbed or ingested; the person
charged with this operation must wear mask, protective goggles and gloves.
All people charged with maintenance operations must be supplied with necessary protective
devices.

 Fill with fluid to convey the pump and the suction piping.

 Open the interception unit in the suction piping.

ATTENTION: the pump must not absolutely operate in dry conditions

ALIGNMENT

VERIFY THE ALIGNMENT AFTER THE ASSEMBLY.

Verify the alignment between motor shaft and pump in order to settle eventual displacement
due to transport.

1. Verify the pump connections are perpendicular and in suitable position; shim the pump if
necessary.

2. If the pump is connected to the motor or reducer by means of a flexible coupling, remove
any protection or cover and verify the alignment of the coupled sections.
If the pump is connected by means of a V belt, verify the alignment with a well tensioned
rope through the faces of the pulley.

3. make a final check after the connection of the piping

4. Reassemble all carters and covers removed for the alignment control.

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PUMP STARTING-UP

STARTING-UP INSTRUCTIONS

The responsible operator of the machine and/or plant where the pump is installed must
prevent unauthorised persons from using it.

After the start-up, the pump must not emit unusual noises; in that case it is necessary to stop it
and individuate the causes.

BEFORE PRESSING THE PUSH-BUTTON “START-UP” VERIFY WHAT FOLLOWS:

1. On the pressure or vacuum indicators (if any assembled on or near the pump) verify if there
are problems on the pump.

2. Verify the coupling alignment.

3. Verify the piping and be sure that there are no stress on the pump casing.

4. Turn the pump shaft and verify it rotates freely.

5. Verify all protections are reassembled correctly and fixed safely.

6. Verify all overpressure devices are fitted correctly and without possibility to separate them
from the pump.

7. Verify the suction piping and be sure that:

 the same are connected and fixed safely

 valves are open
 the piping outlet is below the fluid level

8. Verify the discharge piping and be sure that:

 the same are connected and fixed safely

 valves are open
 the room for the fluid exit is sufficient

9. For stuffing-box pumps loosen the fixing bolts of the packing nut and adjust them to reduce
the product leakage only after the pump has reached the constant temperature. The
stuffing-box should leak lightly to keep it lubricated and cooled.

10. Verify all gauges, indicators and other loosen pieces are placed far from moving parts of
the pump. Verify the suction and discharge valves are open.

11. Connect the electrical supply and move the motor to be sure it turns in the correct
direction.

12. For high operating temperatures (over 150 °C) await the pump has reached the
operating temperature, then check the alignment again. Remind to switch off the electrical
supply before removing the guards and be sure it is connected before starting up again.

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START-UP

If there aren’t problems, the pump begins to supply fluid within 60 seconds from the start-up,
otherwise press “stop” push-button.
Do not turn the pump in dry conditions for more than one minute, otherwise serious damages
could occur.
Repeat the above mentioned steps for the start-up, check the pressure/discharge indicators
and if all is OK fill a little bit of fluid into the pump. A lubricant fluid is suggested to facilitate the
priming.
Press “start” push-button again. If the pump does not supply fluid within two minutes, stop it
again. May be it is necessary to air the discharge piping till the fluid begins to flow.
If it does not pump, repeat all above steps and if everything is regular contact our assistance
service.

Follow these prescriptions for a long and safe pump life, after the start-up:

 Do not turn the pump at a speed higher to the speed stated in the catalogue for your
model.

 Do not expect the pump supplies pressures higher to those stated in the catalogue for your
model.

 Do not start the pump without installed protections.

 Do not use the pump without an overpressure valve on the discharge piping and be sure
the valve is fitted correctly.

The valve inside the pump (if present) is only an overpressure valve. It is also requested to
fit an external relief valve with the same diameter of piping and calibrate it to a pressure
lower than the internal one. The use of the inside valve as by-pass can provide an heat
build up into the pump which could cause dangerous conditions or accidents.

 Spare parts or a complete pump must be stocked in warehouse, specially if the pump is an
essential part of a specific process.

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RESIDUAL RISK ANALYSIS

CAUTION - DANGER

READ FOLLOWING CHAPTER BEFORE OPERATING THE PUMP

The described pump has been manufactured according to Safety Rules of European Union,
and exactly according to Machinery Directive 2006/42/EC and following amendments.
The machine is manufactured considering all risks the Operators can meet and it is equipped
with all guards and signals installed in such a way to avoid accidents to Operators during the
different working processes.
However there are possible residual risks which cannot cause accidents under normal
production conditions but we would like to mention to better protect the operator’s safety.

DANGER FOR FINGERS

During the operation it is absolutely forbidden to touch the moving parts.

Before working on the pump, always stop the machine where it is fitted and switch off the
master switch.

FOR ANY REASON, DO NEVER APPROACH THE PUMP IN FUNCTION.

Do not introduce fingers into the pump connections. The rotating parts could cut if the pump
is in function.

Do not allow the idler gear to rotate idle on the pin. Your fingers could be nipped between
the teeth and the cover (this can occur only with dismounted pump)

ANYWAY DO NEVER OPEN COVERS WITH PUMP IN FUNCTION.

GENERAL RISKS

IDROPRES “E - SERIES” pump is a volumetric pump. This means that when the pump is in
motion, the fluid is fed to the discharge side, and in case the discharge pipe is blocked or
closed, serious problems could occur to the same pump or to the plant. In fact the motor
could stall, the transmission could break and also a pump part can break and piping could
explode.
In order to avoid and prevent these events, the use of an overpressure valve or an other
overpressure device is ESSENTIAL.
An overpressure valve reduces the pressure to a set value, protecting the whole plant. The
overpressure valve assembled on a IDROPRES “E” pump and most of the valves on the line
are preloaded spring type.

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CAUTIONS
The over-pressure valve, internal type, fitted on IDROPRES “E – series” pumps must have the
cover oriented in function of the direction of rotation of the pump. It is designed as over-
pressure valve (see paragraph “START-UP”). The pressure that actuates the internal over-
pressure valve can be modified adjusting the tuning screw.

Electric motors. For the connection of electric motors, follow the local rules in force; be sure
the phases are correct in order to grant the correct rotation direction.

REMARK
The pump does not present remarkable residual risks under normal working conditions.
Dangerous situations can occur due to Operator’s imprudence or unwillingness to keep out of
danger.

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MAINTENANCE AND REPAIR

MAINTENANCE INSTRUCTIONS

Use, maintenance and repairs of the pump are allowed to operators charged by the
responsible of the plant who must know the contents of Instruction Manual.

All control, adjustment, maintenance and lubrication operations must be carried out with
MACHINE OUT OF SERVICE, POWER OFF and EMERGENCY STOP PUSH-BUTTON ON.

For operations requiring power “ON” be careful and employ SKILLED PERSONNEL.

Turn on the power only for strictly necessary time and with greatest care for persons and
machine.

Check no residual pressure is inside the pump or in piping.

In case the pump is still hooked to the transmission during the maintenance operations, be
sure the transmission is locked so that it cannot be started inadvertently while working on the
pump.

Do not let parts fall during the disassembly, i.e. the idler gear can slide from the pin when the
cover is detached from the pump, it could scratch or be notched,

Do not allow the idler gear to rotate idle on the pin. Your fingers could be nipped between
the teeth and the cover.

Remind that some easy maintenance operations like a periodical lubrication, examination of
internal parts, etc. will extend the working life of the pump.

Use original spares only, otherwise the main safety features of the pump cannot be assured.

AT THE END OF REPAIR WORKS

before machine starting up

The plant responsible must verify that all works are finished, all safety devices are in function
regularly and all uninvolved persons are out of the plant.

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TROUBLE SHOOTING

Here below we explain how to read the instruments fitted on delivery and suction line of the
pump.

Indications of the Pressure gauge on delivery line.

An high reading can indicate:

 the interception valve is partially closed;

 an high viscosity or small and/or long delivery line;

 the filter on delivery line can be obstructed;

 a too high calibration of the safety valve;

 the delivery piping can be obstructed;

 the pumped fluid is not at operating temperature;

 an high specific weight not considered;

 the fluid inside the piping can be solidified;

A low reading can indicate:

 by-pass on line is partially open;

 the safety valve does not work properly;

 the pump can have too high internal clearances;

 the safety valve is calibrated at a too low value;

 the pump can be worn-out;

A floating reading can indicate:

 the pump is in cavitation;

 the fluid reaches the pump in intermittent way;

 air could present in suction line;

 some vibrations can be caused by a wrong alignment or by mechanical troubles.

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Indications of the vacuum gauge on suction line

An high reading can indicate:

 the fluid is too viscous to slide inside the piping;

 the suction is too high;

 the suction is blocked;

 the bottom valve is stuck;

 the interception valve is closed;

 the filter is clogged;

A low reading can indicate:

 the end of the suction pipe does not suck the fluid;

 air has come into piping;

 the pump is worn-out;

An erratic, floating, spring reading can indicate:

 the pump is not primed;

 the fluid evaporates;

 the suction is not enough;

 discontinuous arrival of the fluid to the pump.

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Here under you will find general solutions suggested for some problems that may occur:

1. The pump absorbs too much power.

 It turns faster than foreseen. Check motor, reducer, pulleys etc.

 Viscosity higher than foreseen;

Increase the diameters of the piping, reduce the speed, use a more powerful motor.

 Delivery pressures higher than foreseen: check with a pressure gauge.

Increase the diameter of the delivery piping, reduce the speed, use a more powerful motor.

 Stuffing box set too tight. Set it properly.

 Misaligned pump. Check alignment.

 Insufficient internal clearances inside the pump for the operating conditions. Increase the
tolerances.

2. Early wear of the pump.

 Generally it takes months or years before the pump decreases its performances. The wear is
generally equally distributed. When the wear is early, the wear presents deep rulings, too
polished parts, uneven consumption.

3. The pump does not pump.

 Interrupted priming. Air inlet inside the suction piping. Low fluid level in the tank, bottom valve
stuck.

 Too elevate suction.

 Wrong rotation direction.

 The motor does not reach the foreseen speed.

 Interception valves on suction or delivery line, are closed.

 Clogged filter on suction line.

 By-pass valve is open, safety valve is open.

 The pump is worn-out.

 Changes in the system such as additional tanks, new suction lines, unskilled operators, etc.

 Too much clearance between rotor and cover.

 Cover placed incorrectly.

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4. The pump starts and then it does not prime.

 Empty tank.

 Fluid evaporated in the suction line.

 Air entry in the suction or sealing line.

 The pump is worn-out.

5. The pump makes noise.

 The pump does not receive sufficient fluid. Increase the diameter of the suction piping or
reduce its length.

 The pump is having cavitation (the suction fluid evaporates); Increase the diameter of the
suction piping or reduce its length, increase the positive shutter or reduce the negative one.

 Defective alignment. Check it.

 Shaft or rotor tooth is bent. Straighten it, or better, replace it.

 The safety valve makes noise. Increase the calibration pressure.

 Anchor the baseplate or pipes to reduce vibrations.

6. Output lower than what foreseen

 Lack of feeding or pump is in cavitation.

 Filter partially clogged.

 Air coming in suction or from sealing.

 Motor turns slower than foreseen. Check motor and reducer.

 By-pass line partially open.

 Safety valve calibrated too low or remained open.

 The pump is worn out.

 Reduce clearance between cover and rotors.

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FUNCTION ANOMALIES

TROUBLE CAUSE REMEDY

Scratches or dings caused by big and Remove the pump from the
Abrasion hard particles, circuit.
Early consumption of bushes and pin. Apply a filter on suction line.
Sometimes it is necessary to
repeat this operation before
cleaning the circuit.
.
Rust, metal attached on wide surfaces, Check if the used materials are
Corrosion metal scales or decays. suitable for the application.

Check if the fluid has not been

polluted and made more
corrosive by the presence of
other fluids not foreseen.

Function under Noise, broken bushes, bent shafts, parts Check the pump runs within the
conditions higher that show to have been overheated. limits foreseen for this particular
than those model.
foreseen in the
catalogue.

The pump can block. Increase the clearances or

Insufficient Seizing-up signs among rotor, body contact the suppliers to ask for
clearances and head. information.

Consumption on one side only such as Check the unit alignment and
Cross-axing body, stuffing box and head. piping does not stress the pump.

The pump blocks, seizing-up of the Be sure the fluid arrives to the
Dry function parts in touch, sealing seats and pins pump. Put levels in the tanks.
change colour due to excessive
heating.

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NOISE

The pump, normally used and correctly installed, does not cause high noise. If this occurs stop
the pump immediately because this means that there is an anomaly inside the pump or in
the plant connected to it. High noise is often caused by pump in cavitation.

INSTRUCTIONS FOR FIRES

The standard pump, for its construction, is not normally subject to risk of fire.
However, for use in hazardous environments or with flammable liquids, it is suggested to
report it to our technicians to evaluate the use of a specially designed pump.

INFORMATION FOR OBNOXIOUS SUBSTANCE WASTE DISPOSAL

Conform to EU prescriptions and local rules in force.

INFORMATION FOR PUMP DISPOSAL

The pump demolition produces metal wastes. It is sufficient to follow current prescriptions and
local rules in force regarding the getting rid of unobnoxous wastes.

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SPARE PARTS

1 5 9 4
SEZIONE A BADERNA
Packing pump section

8 17 18 3 12 10 13
11

6
2

16
7

11
PARTICOLARE TEN.MECCANICA
Mechanical seal detail
19
22
24
25
21
26
20

PARTICOLARE Anelli Ten. LIP

Radial seal detail
6

Pos. Descrizione Description

1 Corpo pompa Casing pump
2 Coperchio pompa Pump cover
3 Supporto cuscinetto Bearing support
4 Ruota comando Gear drive
5 Satellite Idler gear
6 Albero (ceramizzato in vers. LIP) Shaft (ceramized in LIP Version)
7 Perno Satellite Idler gear pin
8 Boccola albero Shaft bushing
9 Boccola satellite Idler gear bushing
10 Cuscinetto a sfere Ball bearing
11 Guarnizione corpo Casing gasket
12 Seeger Seeger
13 Chiavetta Key
16 Nilos Nilos ring
17 Baderna Packing
18 Premitreccia Packing gland
19 Seeger tenuta meccanica Mechanical seal seeger
20 Alloggiamento tenuta meccanica Seal holder plate
21 Anello fisso tenuta meccanica Stationary seat ring
22 Anello rotante tenuta meccanica Mechanical seal rotary ring
24 Pressello Packing nut
25 Distanziali anelli tenuta Seal ring washer
26 Anelli tenuta LIP Seal ring LIP type

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10 3 4 2 6 9 7 8

Valvola di sicurezza a molla

Regolabile
Safety spring valve
Adjustable

1 5
Pos. Descrizione Description
1 Corpo By-Pass By-Pass Body
2 Coperchietto By-Pass By-Pass cover
3 Valvola Valve
4 Piattello Plate
5 Molla Spring
6 Vite regolazione Tuning screw
7 Dado Bloccaggio Blocking nut
By-Pass completo Coperchio regolazione Tuning cover
8
9 Guarnizione dado Casing nut
10 Guarn.Coperchietto Casing cover

Esecuzione Standard
Tenuta meccanica semplice

Standard Execution
Simple Mechanical Seal

Esecuzione Tandem
Tenuta meccanica doppia in tandem

Tandem Execution
Double Tandem Mechanical Seal

Esecuzione Combinata
Ten.meccanica con abbinato liquido di sbarramento

Combined Execution
Mechanical Seal joined with liquid barrage

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