ALLWEILER

1

Operating and Maintenance Instructions including Disassembly and Assembly Instructions

Hydraulic I Keep for future use!

ID No.: Order No.:

Series No.:

Contents

0. Brief instructions

1. General

2. Safety

3. Transportation and interim storage

4. Description

5. Design of system

6. Installation of pump

7. Start-up and switch-off

8. Maintenance

9. Servicing, disassembly and reassem-bly

10. Faults, causes and remedies

11. Ancillary documentation

12. Identification

!

These operating and maintenance instructions contain information by the pump manufac-turer. They may have to be supplemented by instructions of the operating company. Specific information for the operation and maintenance of the technical system in which the pump is integrated, is not included. This can only be provided by the company respon-sible for the installation and design of the sys-tem (system manufacturer). Such specific information for the operation and maintenance of the technical system in which the pump is integrated has prior-ity over the information provided by the pump manufacturer. See operating instruction of system manu-facturer!

ALLWEILER

2

0. Brief instructions for commissioning a supplied complete pump unit. ● The pumped fluid may not have a tendency to crystallise and may not contain any solids, having an

abrasive effect (see Section 1.1. Use and areas of application). ● Remove protective seals from connection pieces prior to connecting the pipes. ● If the pump has been preserved, drain off preservation agent (dispose of correctly!) and clean

pump. ● Align pump or pump unit on foundation and secure. ● Clean pipe system. ● Observe direction of flow and rotation (see arrows on pump). ● Fill pump with pumping medium (pump must be fully ventilated). ● All shut-off fittings in the suction and delivery pipe must be opened. ● Check that the coupling protection is installed and that all safety devices are operational. ● Install motor circuit breaker. Electrical connection must be provided by a qualified electrician! Check

voltage, speed and direction of rotation. ● Turn pump manually and check for light, even movement. ● Switch on motor. ● Once the operating speed has been reached, check the operational pressure on the pressure gauge,

regulating the operating point by throttling on the delivery side, where necessary. ● The delivery volume may not fall below a specified minimum. ● The pump must always be supplied with fluid and may never run dry! ● Generally do not touch pumps in operation as they might be hot. ● The power required increases with an increase in lift height and a decreasing pumping volume! ● The pump may never be started or operated with the suction and/or delivery side closed. ● Neither during installation nor during operation may pipe runs transfer any stresses onto the pump.

! The safety instructions specified under Section 2-ff must be observed!

ALLWEILER

3

1. General 1.1 Use and areas of application

The pump is a self-priming periphery pump. It is suit-able for pumping clear and cloudy as well as gase-ous fluids, not containing any abrasive constitu-ents. The pump is designed as a multi-stage sectional case pump. The use of uniform components for sev-eral pump series and sizes allows economic stock-keeping and procurement of spare parts. The pump is driven by an electrical motor. The pump may only be used for operating conditions specified by the client and confirmed by the supplier. The correct use is stipulated in the datasheet en-closed in the Appendix.

!

This pump may only be used for the purpose stipulated in the datasheet as it may otherwise be hazardous for people and the environment. The pump may not be operated below or above the density stated in the datasheet as otherwise the pump may be damaged.

!

Systems in which the breakdown or failure could lead to injury or damage must be equipped with alarms and/or stand-bye units and their function-ing must be regularly checked. Units directly or indirectly linked to drinking wa-ter systems must be freed from any impurities prior to installation and commissioning.

!

Operational pumps should generally not be touched as they may be hot.

In general, the data relating to speed, pressure and temperature specified in the datasheet are deemed to be the values at which the correct function of the pump is guaranteed. It is not permitted to deviate from these values.

!

In case of a closed delivery pipe, the temperature of the pumped medium in the pump rises. As a result, overpressure that may be hazardous is created. Special hazards are created by higher temperatures in case of easily combustible or flammable media. This may lead to an explosion. These hazards are avoided by installing a bypass system with a pressure control valve. Specified supply pressures (system pressures) may also not be exceeded. Where no pressures and/or temperatures are stipulated in the order confirmation, the pressure and temperature limits specified in the brochure apply as long as these values are not fur-ther limited by the used shaft seals.

1.2 Testing Prior to leaving our works, all pumps are thoroughly tested on our test stand.

Only correctly operating pumps, achieving the agreed performances under the specified tolerances leave our works. Provided the below operating in-structions are observed, the fault-free operation and full pumping performance is thus guaranteed. Test pressure = 1.5 x pump operating pressure

1.3 Characteristic curve of the side channel pumps

Fig. 1.1

Fig. 1.2

Fig. 1.3 Requirements: 1. Start with opened slides. 2. Never operate with closed delivery pipe. 3. Only operate in the range Qmin to Qmax.

1.4 Guarantee Our liability for deficiencies in supply is specified in our terms of delivery. We do not accept any liability for damage resulting from the non-compliance with the operating instructions and conditions of use. Where operating conditions change at a future point in time (i.e. different pumped medium, speed, viscos-ity, temperature or supply conditions), it must be es-tablished in each case and, where necessary con-firmed that the pump is suited for this changed condi-tion. Unless otherwise agreed, pumps supplied by us may only be opened or changed by ourselves or at authorised customer service centres during the pe-riod of guarantee. Non-compliance cancels our liabil-ity for any deficiencies.

ALLWEILER

4

1.5 Sound level Depending on the pump size, the sound level of our pump lies between 60 and 72 dB(a). This noise is, however, not only caused by our pumps. Noise can also be produced by: ● drive units ● incorrectly installed couplings ● other appliances in the same room (i.e. heating) ● water pipes, water taps or valves. Flowing water

always generates noise (i.e. water hammer). It is, however, possible to reduce these noises by suitable measures to an acceptable level.

The flow speeds of the water should be kept as low as possible. In order to reduce the flow speed, adequately dimen-sioned pipe runs, pressure reducers and devices are particularly effective. Where the pump generates most of the noise, the noise level can be reduced by the following meas-ures: 1. Install pump on rubber buffers. 2. Insert a rubber connection piece in the suction

and delivery pipe between the pump and the pipe system.

3. Pipe runs should not be in direct contact with walls, ceilings, and floors.

4. Where necessary, surround pumps (not motor) with a soundproof housing.

2. Safety These operating instructions contain basic informa-tion that must be observed for the installation, opera-tion and maintenance. The operating instructions must, therefore, be read by the fitter and the respec-tive trained personal / user prior to the installation and start-up and must be kept with the ma-chine/system at all times. In addition to the general safety instructions specified in this main section, also special safety instructions listed under other main sections - such as for private use - must be complied with. These Operating In-structions do not replace local safety regulations.

2.1 Identification of safety information in the operat-ing instructions Safety information contained in these Operating In-structions, which if not complied with can result in a hazard for the personnel, are specially identified with a general hazard symbol:

! Hazard symbol acc. to ISO 3864-B.3.1

Safety information relating to electrical hazards are specially identified with:

Hazard symbol acc. to ISO 3864-B.3.6

In case of safety information whose non-compliance could be hazardous for the machine and its function, the word

CAUTION has been added. Instructions given on the machine itself, such as direction of rotation arrows, symbols for fluid connections must be observed and main-tained in a fully legible condition.

2.2 Qualifications and training of personnel Personnel carrying out the operation, maintenance, inspection and installation must be suitably qualified for these tasks. The areas of responsibility, duties and monitoring of the personnel must be precisely specified by the user. Where the personnel does hot have the required knowledge, employees must be trained and instructed. Where required, this training can be carried out by the manufacturer/supplier of the machine on behalf of the user. The user must also ensure that the contents of the operating instructions are fully understood by his personnel.

2.3 Hazards in case of non-compliance with safety instructions Non-compliance with safety instructions can endan-ger the personnel, the environment and the machine. Non-compliance with safety instructions can also void any liability claims. Non-compliance with safety instructions could, for in-stance, result in the following hazards: ● Failure of important machine/plant functions ● Failure of stipulated maintenance and servicing

methods ● Endangering of personnel due to mechanical and

chemical effects ● Endangering of the environment as a result of the

leaking of hazardous substances

2.4 Safe working procedures The safety instructions contained in these Operating Instructions, all existing national accident prevention regulations as well as all internal work, operating and safety instructions issued by the user, must be com-plied with.

2.5 Safety information for users/operators ● Where hot or cold machine parts may cause haz-

ards, these parts must be protected by a guard. ● Guards shielding moving parts (i.e. coupling

protection) may not be removed whilst the machine is running.

● Leaks (i.e. in the shaft seal) of hazardous pumped substances (i.e. explosive, toxic, hot) must be disposed off in such a way that neither the personnel nor the environment are endan-gered. Legal regulations must be complied with.

● Any electrical hazards must be prevented (for de-tails see VDE regulations and information from your energy supply company).

ALLWEILER

5

2.6 Safety information for maintenance, inspection and installation work The user must ensure that all maintenance, servicing and installation work is carried out by authorised and qualified trained staff who have gained the necessary information by studying the operating instructions. In general, any work on the machine must only be carried out once the machine has been shut down. The procedures for shutting down the machine, stipulated in the Operating Instructions, must be complied with. Pumps or pump assemblies, pumping potentially harmful substances, must be decontaminated. Pumps forwarded to us for repair, must be cleaned in such a way that our employees are not exposed to any health hazards. Immediately after completion of the work, all safety equipment and guards must be re-installed and/or started. Prior to starting up the machine again, , sections 7.1, 7.3 and 7.4 must be observed.

2.7 Reconstruction and manufacture of spare parts by the user Reconstruction or changes to the machine are only permitted with the prior approval of the manufacturer. Original spare parts and accessories authorised by the manufacturer ensure the safe operation of the machine. The use of other parts may void the liability of the manufacturer for any resulting consequences.

2.8 Unauthorised operation The safe operation of the machine can only be guar-anteed, if the machine is operated as stipulated in section 1 of these operating instructions. The limits specified in that datasheet may not be exceeded at any time.

3. Transportation and interim storage 3.1 Safety measures

! Never stand under loads moved by cranes.

Always keep a safe distance to transported loads. Only use permissible and correctly working lift-ing gear. Match the length of the lifting gear elements so that the pump or the unit is suspended straight. Do not remove any information or documents at-tached to the pump. Handle the pump carefully.

3.2 Packaging The symbols contained on the packaging must be observed. The inlet and delivery sides of the pump must be closed with plugs during transportation and storage. The flanged connections must be removed during installation of the pump unit.

3.3 Unpacking

Prior to unpacking, the packaging should be visually inspected. Any noted transportation damage should be listed on the receipt or delivery note. Any claims should be immediately forwarded to the shipping agent and/or the transport insurance company.

3.4 Interim storage If the pump or the unit are not installed immediately after delivery, the machine must be stored in a dry room free from vibrations.

3.5 Transportation The pump must be correctly transported. Figs. 3.1-3.3 show the correct handling.

!

Where the pump unit is transported by a crane, the crane and the sling gear must be sufficiently dimensioned. The sling gear may not be con-nected to the suspension eyes of the motor!

Fig. 3.1 Pump and motor on base plate

Fig. 3.2 Pump in block design

ALLWEILER

6

Fig. 3.3 Pump with vertical design

3.6 Preservation If the pump has been preserved by our works, this is shown by: 1. The sign attached to the pump. 2. The respective information on the delivery note and invoice. CAUTION The preservation protection will last for six months. Please observe that all pumps produced from grey cast iron and nodular iron that have been operated (even for just a trial run), must be protected against corrosion when placed out of service. Exter-nal and internal preservation measures have to be carried out and instructions 3.6.1 + 3.6.2 apply.

3.6.1 Preservation agents The below specified preservation agent can be used for external and internal preservation. ● Preservation agent:

SHELL FLUID BD22, Deutsche Shell AG, Frank-furt.

In case of an external preservation, all air and un-coated parts such as shaft ends, flanged surfaces, etc. are preserved. The preservation agent is painted or sprayed with a spray gun. In case of internal pres-ervation, the housing, shafts, impellers and the shaft seal are preserved. The preservation agent is ap-plied by filling the pump. During filling, the shaft should be slowly turned in the normal direction of ro-tation. The pump should be filled until the preserva-tion agent has reached the sealing strips of the de-livery and suction flange without any air inclusions. The delivery side and suction side must then be closed with a blank flange. NOTE: The specified preservation agent is the recommend agent. Preservation agents with other preservation characteristics from other mineral oil manufacturers may also be used.

According to the specifications by the conservation agent manufacturer, the preservation agent offers a protection of 6 months. The active ingredients con-tained in this preservation agent also offer adequate anti-corrosion protection in case of high humidity (sea, tropical climate).

3.6.2 Removal of preservation agent and disposal Prior to start-up, the applied preservation agent must be removed. Any internal preservation must be drained off.

!

Preservation agent must be disposed off cor-rectly!

The pump must be completely cleaned. This applies, in particular, for pumps used in the food or drinking water supply sector. A suitable solvent, compatible with the pumped me-dium (foodstuff) can be used as a cleaning agent for removing the internal and external preservation agent.

3.7 Storage and monitoring preservation In case of longer storage, the operator must check the conservation of the pump in regular intervals. The filling level of the pump must be checked every six months. Where required, preservation agent must be replenished up to sealing strip level at the delivery flange.

4. Description 4.1 Constructive design

Self-priming, sectional case pump operating accord-ing to the periphery pump principle. The performance of the peripheral pump depends a. o. on the gap be-tween the impeller and the stepped housing (0.15 to 0.17 mm) Due to the narrow gap widths, the pump is not suitable for pumping media containing solid particles (in special cases, a filter must be installed on the suction side).

4.2 Housing The suction and delivery housing as well as the suc-tion and delivery sides are laterally divided. Flat packings are used as seals between the housing and housing components.

4.3 Position of connection pieces / flanges / dimen-sions see datasheet

4.4 Additional connections The delivery housing of the pump contains: ● 1 screw-in stopper for connecting a pressure

gauge. ● 1 screw-in stopper for draining the fluid.

ALLWEILER

7

The suction housing of the pump contains: ● 1 screw-in stopper for connecting a mano-

vacuummeter. ● 1 screw-in stopper for draining the fluid (complete

drainage is not possible).

4.5 Impellers Open, star-shaped impellers with relief holes provid-ing axial-thrust compensation.

4.6 Shaft The pump is equipped with a special deflection-resistant shaft, ensuring a smooth operation during all load phases.

4.7 Storage and preservation see datasheet

4.8 Drive The pumps are driven by an electric motor. In most cases, totally enclosed fan-cooled A.C. cage motors, series B3 or B14, protection type IP44/54 acc. to IEC standard, insulation class B, motor winding for 380 V or 660 V, 50 or 60 Hz are used. Explosion-proof mo-tors and other types can also be provided.

4.9 Coupling and shock protection A flexible coupling by Flender, type N-Eupex, series B, is used for our pumps. Important note for installing the coupling: Only use couplings, where the coupling half on the pump side can be secured in axial direction with the nut on the shaft end. Turn or rework hole in hub on pump-sided coupling half in such a way that the cou-pling half can be easily slid onto the shaft end. Do not use hammer!

!

For accident prevention, the pump must be shock protected acc. to DIN 31001. Where explo-sive substances are pumped, the protection must be made from a material that cannot produce sparks (i.e. brass).

4.10 Accessory The supplied accessory is specified in the datasheet. The respective Operating and Installation Instruc-tions for the accessory are also enclosed in the Ap-pendix. If you wish to install other accessory on the pump or pump unit, please inform the manufacturer about the accessory to be installed.

5. Design of system 5.1 Pipe system

CAUTION The arrows indicating the direction of flow on the pipe connection of the pump must be observed. The nominal width of the pipes must correspond with the nominal width of the pump connection section (see datasheet). Ensure that the pipes have been cleaned prior to pump installation. Support the pipework to ensure that no stresses are transferred to the pump (pump parts may break). Avoid large cross-sectional transitions and changes of direction. A different nominal width can be compensated for by eccentric transition sections. This pre-vents the formation of any air inclusions in the pipe system. Prior to the connection piece of the pump a smoothing section with the diameter of the nominal width of the suction section and a length, ten times the diameter of the suction connection should be installed. This will prevent cavitation. The flow speed in the suction and/or feed line should not exceed 1 m/s.

5.1.1 Nominal width The pipes must be dimensioned in such a way that a correct supply flow to the pump is guaranteed and the function of the pump is thus not impaired. The suction and delivery side should have a flow speed of approx. 1 m/s. Special attention should be paid to the air-tightness of the suction pipe and compliance with NPSH val-ues.

5.1.2 Changes in cross-section and direction The direction of flow through the pump body is indi-cated by arrows on the pump housing. Sudden changes in cross-section and direction as well as sharp bends must be avoided.

5.1.3 Support and flange connections The pipes must be connected free from stress, should be supported close to the pumps and should be easy to secure to avoid any distortion. Once the bolts are released, the flanges should still rest against each other, should not bounce off each other or press against each other. The pump must be pro-tected against thermal stresses in the pipe system by suitable measures, i.e. the installation of compensa-tors. Hydraulic forces must also be absorbed by suit-able pipe fixings before and after the pump.

ALLWEILER

8

5.1.4 Cleaning of pipe system prior to installation CAUTION It must be observed that the pipe runs are completely clean prior to start-up. They may not contain any welding beads, burrs, rust, etc. None of the flange seals may protrude internally. The correct seal of the connections must be checked. (See Section 3.6 Preservation).

!

Do not drain-off anti-corrosion agent with wastewater!

5.2 Suction pipe

In order to guarantee a cavity-free operation, Section 5.4 Supply conditions must be observed. The suction line can be installed in any suitable manner. It can run through the pump as the pump can also suck up media uphill. The cross-section of the suction pipe may not be smaller than the suction pipe connection of the pump. A flow speed of 1 m/s should be en-sured in the suction pipe. In case of difficult suction-side conditions, a smoothing section, having a length of ten times the pipe diameter before entry into the pump, must be installed. In the suction operation, the suction basket must be at least 0.2 m below the low-est fluid level (see Fig. 5.1).

Return valve

Suction basket(Return valve)

Fig. 5.1 CAUTION In order to maintain its self-priming state, the pump must constantly be filled with pumping media. The peripheral pump is able to supply air or gas with the pumped media and to evacuate a suction pipe. The pumps must first be filled or have been filled with liquid. The suction ability is limited a vacuumetric lift of approx. 7 m (for water 20°) and reduces with in-creasing wear. The suction time is limited from one to max. two minutes as the suction stagnates due to the medium warming in the pump. In order to prevent drainage of the pump after switch-off, a return valve must be provided on the suction side (see Fig. 5.1). For the supply operation, the fluid level must be kept at at least 0.5 m above the pipe connection. In case of the medium being supplied from a container and a vacuum, an equalising pipe (AL) should be installed (see Fig. 5.2).

Return valve

Fig. 5.2

5.3 Delivery pipe The pipes on the delivery side should also have a constant cross-section. In case of higher pumping lifts and longer pressure pipes it is sensible, to pro-vide a soft-closing return valve (see Fig.5.1 + 5.2).

5.4 Supply conditions (NPSH) In order to guarantee a fault-free continuous opera-tion, the supply and/or suction conditions of the plant must be adapted to the pump requirements (NPSH). The operating conditions are fulfilled if the NPSH value of the plant (NPSHexist) is higher than the pump NPSH normal value (NPSHact). NPSHexist > NPSHact The (NPSHexist) is specified in the characteristic dia-grams for each pump type. On request, we can provide forms for calculating the NPSH normal values. In the suction operation it must be observed that the geodetic lift of 7 m (for water at 20°C is not ex-ceeded). Please observe, in case of pumping agents with low evaporation pressures or water with tem-peratures of above 20°C that the lift of the pump will decrease accordingly. CAUTION Where media close to the boiling point is pumped, the supply height and/or the NPSH value must be observed as a cavitation will oth-erwise be created in the pump and this could lead to the destruction of the hydraulic system.

5.5 Information relating to the design and construc-tion of boiler plants 1. Design supply pump with a respective reserve

according to TRD 401. 2. In case of two possible pump types the pump

with the better NPSH value should always be chosen.

3. The length of the suction and delivery pipe of the

boiler supply pump should be kept as short as

ALLWEILER

9

possible and should include as few as possible bends and elbows.

4. The suction pipe should be one nominal width

larger than the connection at the suction housing. There should be no abrupt reductions in the pipes.

5. In case of the parallel operation of two pumps,

each pump is assigned to its own suction pipe (see Fig. 5.3).

6. The connection of the suction pipe to the supply

container should never be vertical but always horizontal. This prevents the creation of any tur-bulence (see Fi. 5.3).

Incorrect! Correct!

Fig. 5.3 7. Ensure that the feed pump never runs dry 8. In case of over-dimension pumps, install a throttle

unit in the delivery pipe. 9. Compensators should be installed in the suction

and delivery pipes. Also, a filter should be in-stalled in the suction pipe and a return valve in the delivery pipe (see Fig. 5.3).

10. Do not install any volume-dependent control

valves in the delivery pipe of the pump. 11. When dimensioning the system, the worst NPSH

value with the smallest possible pumping pres-sure of the pump must be taken into considera-tion.

12. Pressure-sensing equipment should be provided

on the suction and delivery side. 13. The sliders on the suction and delivery pipes

should be designed in such a way that they are not inadvertently closed.

14. In case of a smaller than intended differential

pressure, the feed pump operates in a worse NPSH range. In order to prevent any damage, the pump should consequently be respectively throttled (see Fig. 5.4).

Pressure decreases!

NPSH increases!

Fig. 5.4

5.6 Safety devices Speed, pressure and temperature Suitable safety measures must be provided on the plant side to ensure that the limits for speed, pres-sure and temperature, specified in the datasheet, are guaranteed not to be exceeded (see DIN 24295, Section 3.4). Stoppers, flushing, cooling Suitable regulating and control options must be pro-vided for any existing flushing or blocking systems. For the required quantities and pressures, see de-scription of shaft seals (see Section 8. Maintenance). In case of hazardous pumping media or high tem-peratures, it must be ensured that the pump is put out of action in case of a failure of the blocking or flushing system. The blocking and flushing system must be in operation prior to the start of the pump. The systems may only be taken out of order during stand-still of the pump, if at all, based on the type of operation (see Section 7. Start-up and switch-off). Minimum volumes, operating range The operating range specified in the specification sheets must be complied with and may neither be fallen short of or exceeded. The left characteristic limit represents the minimum volume for the pump. The minimum volume for the pump must be ensured under all operating conditions by using suitable measures on the plant side, such as free-running re-turn valves or a bypass. Ensure that the transmission rate is not exceeded. On request, we will be happy to assist you with the design of the free-running return valves or bypass. The suction and delivery side of the pump must be equipped with a manometer/vacuum or pressure gauge. In order to accurately maintain the lifting height (see rating plate), a throttle must be provided on the delivery side. In case of higher lifts (<20 m), long pipe runs, parallel operation and planned-specific counterpressures (system pressure), a return valve (R) must be installed to prevent the medium from flowing back through the pump once the unit is switched off (see Fig. 5.1 + 5.2).

5.7 Electrical connections

The mains cable of the coupled drive motor must be connected by a qualified electrician according to the circuit diagram provided by the motor manufacturer. For this purpose, the valid VDE regulations and the regulations of the local utility company must be observed. Any electrical haz-ard must be prevented.

5.8 Inspection After completion of the installation, the impervious-ness of all pipe runs and connections must be checked. It must also be checked that the unit does not contain any blockage (it must be possible to turn the shafting manually).

ALLWEILER

10

!

Based on the valid accident prevention regula-tions, the operational safety of the plant must be checked (electrical connections, coupling protec-tion etc).

5.9 Hydrostatic compression test If a hydrostatic pressure test is carried out on the pipe system, the pump should not be included in the test. If the pipe system cannot be pressurised without the pump, it must be ensured that no foreign bodies en-ter the pump. The pump may only be pressurised with 1.3 x the nominal pressure of the pump. The nominal pressure is specified in the datasheet. For pumps with a stuffing box, the packing must be replaced after the pressure test (as incorrectly com-pressed – no longer suitable for operation). Where the pipe is emptied after the pressure test, the pump must be correctly preserved (otherwise rusting and problems with start-up). The connection of the pipe to the pump must ensure that the arising reaction forces of the pipe do not exceed the maximum per-missible suction forces and suction moments under any operation. Prior to start-up, the pipe system and installed fit-tings, devices, etc. must be cleaned from any impuri-ties such as welding beads, forging scale, etc.

6. Installation of pump 6.1 Safety measures

!

The pipe runs must be carefully connected as otherwise pumping media would exit during the operation of the pump and cause a hazard for the operating personnel. Ensure that the suction and/or supply pipes as well as the delivery pipe are valved off.

Ensure that all electrical connections are not under voltage. Otherwise there is a danger of electrocution.

6.2 Installation tools No special tools are required for assembly and instal-lation.

6.3 First installation 6.3.1 Permissible ambient conditions

The ambient temperature may lie between –20°C and plus 40°C. The humidity should be as slow as possible, to prevent corrosion.

6.3.2 Floor, foundation The pump must be installed on an even, vibration-free floor or foundation. Vibrations reducing feet must be used, where necessary.

6.3.3 Required installation area

The dimensions for the required installation area of the pump unit are shown in the dimensional table. It must be ensured that the switch-off and control equipment as well as the measuring devices can be easily accessed. CAUTION Sufficient room must be provided for maintenance and servicing, in particular for changing the drive motor or the complete pump unit.

6.3.4 Checking the installation Prior to installing the pump in the plant, the following points should be checked: ● Is the electrical connection for the drive motor

free from any voltage? ● Are the suction or supply pipe and delivery pipes

empty and are they respective valves closed? ● Can the pump be easily turned manually (turning

the ventilator of the motor)? ● Have all existing internal regulations been ob-

served?

6.3.5 Installation of pump and mounting in pipe system The pump must be aligned with the pipe runs. The pipe runs must be supported in such a way that no distortion occurs once the pump is connected. When tightening the bolts, the following sequence must be observed: 1. Tighten the flange connection. Remove protective

caps of pipe sections prior to connection of the pipe runs.

2. Secure the pump and motor feed. The motor and

pump feed should only be tightened by hand.

6.3.6 Checking the flexible coupling After connection of the pipe run, the direction of the coupling must be checked and adjusted where nec-essary.

Ruler

Fig. 6.1 Alignment, using fine ruler

ALLWEILER

11

Fig. 6.2 Alignment, using dial gauge

Fig. 6.3 Alignment, using dial gauge Permissible offset for flexible couplings (only ap-plies for supplied original couplings):

Permissible shaft offset

Size radial ∆Kr

mm

angled ∆Kw

Smax – Smin mm

axial ∆Ks

Smin up to Smax mm

1(58) 0.10 0.10 2…4 2(68) 0.11 0.11 2…4 3(80) 0.13 0.13 2…4 4(95) 0.15 0.15 2…4

5(110) 0.18 0.18 2…4 6(125) 0.21 0.21 2…4 7(140) 0.24 0.24 2…4 8(160) 0.27 0.27 2…5

Speed factorS max = 1.5n

N-E

UPE

X si

ze

Speed n [1/min.] Fig. 6.4 ∆Kr and ∆Kw are valid for shock-free operation and ambient temperatures of -30°C to 80°C. Permissible offset ∆Kr x Sn or ∆Kw x Sn. Sn = speed factor ∆Kr and ∆Kw can occur simultaneously. The total of both offsets may not exceed ∆Kr or ∆Kw .

Radial offset

Fig. 6.5

Angled offset

Fig. 6.6

Axial offset

Fig. 6.7

!

The coupling must be protected against contact with a protection device acc. to DIN 31001 in order to prevent any accidents.

6.4 Protection and control devices The existing protection and control devices must be installed and connected in accordance with the re-spective instructions.

!

A protective motor switch must be supplied. In case of any work being carried out on compo-nents carrying voltage, the mains plug must be pulled out or the mains switch must be switched off and the fuse must be removed. Ensure that nobody is able to restart the unit whilst work is carried out on the motor.

6.5 Final checks The following final checks must be carried out: 1. Check that connecting flanges are properly seal-

ing. 2. Check that the pump is running easily.

ALLWEILER

12

7. Start-up and switch-off

7.1 Safety measures

Electrical connections must be designed to com-ply with the regulations of the local utility com-pany as well as the stipulations of ElexV. In addi-tion the ElexV guidelines of BG-Chemie must also be complied with. This work may only be carried out by respectively authorised personnel.

!

The pump must be correctly filled as otherwise the pump may be damaged.

When using hot pumping media, the pump should be filled slowly to prevent any distortion or thermal shock. In case of explosive, toxic, hot or corrosive me-dia it must be ensured that no hazard occurs for persons or the environment. The pumped volume should only be regulated on the delivery side during constant speed. The con-trol fittings on the suction and/or feed side must be fully opened during operation.

7.2 Start-up preparations 7.2.1 Filling the pump

The pump must be fully filled with pumping media. The system must be vented via the auxiliary connec-tions at the flanges. This only occurs once and can possibly be carried out prior to the connection of the pipe. During subsequent start-ups the pump is self-priming. Easy operation of the pump shaft must be checked. The readiness of all auxiliary connections must be checked. All shut-off fittings in the suction and deliv-ery pipe must be opened. Where media with tem-peratures of <100°C is pumped, the pump (pump body) must be heated prior to start-up. This is best done by using hot media to fill and flow through the pump body until it has approximately reached the temperature of the media – at least 10 min. CAUTION The pumps may not run dry under any circumstances! Heating-up can destroy pump components.

7.2.2 Drive motor

The electrical connection must be carried out by a qualified electrician, observing VDE and local regulations, in particular, with regards to protec-tive measures. Check operating voltage and speed of motor. Speed at 50 Hz: 1450 1/min. or at 60 Hz: 1750 1/min. A protective motor switch must be provided!

7.2.3 Storage The bearings are filled with sufficient grease by the manufacturer and are thus operational.

7.2.4 Checking direction of rotation The direction of rotation of the motor must corre-spond with the directional arrows on the pump. Re-spective arrows are shown on the pump. To check the direction of rotation, the motor can be briefly switched on. An incorrect direction of rotation can damage the pump. CAUTION Never run pump against specified di-rection of rotation! Only check direction of rota-tion on filled pump!

7.3 Start-up 7.3.1 Start

Switch on motor! CAUTION Never start or operate pump (even briefly!) against a closed delivery side! Switch on pump with shut-off unit open. Also, all sliders contained in the suction pipe must be opened. Any existing bypasses must be closed in the suction operation. The bypass can remain open during sup-ply operation. Once the unit has reached the nominal speed (see rating plate) the lift should be adjusted by slowly closing the fitting on the delivery side. The suction time depends on the length of the suc-tion pipe and will be several seconds for the first time. In case of the use of a foot or return valve in the suction pipe, pumping starts immediately upon the pump being switched on again.

7.3.2 Adjusting pumping output The pumping volume can only be adjusted once the correct pumping speed is attained. The operating data of the pump is specified on the rating plate and in the datasheet. The produced lift should be con-trolled, using the pressure gauge and should be ad-justed on the delivery side in case of any deviation. Even during operation, never operate against closed delivery side! CAUTION In case of the pressure in the exit cross-section of the pump showing an impermis-sible increase due to operational malfunction, suitable safety measures (i.e. installation of relief valve) should be implemented on the plant side.

7.3.3 Maintaining a minimum flow volume In order to prevent any damage to the pump, any operation against the closed shut-off slider of the de-livery pipe must be avoided. Safety measures on the plant side (i.e. overflow valve) must be used to ensure that the operational pressure of the pump is not exceeded as a result of malfunctioning during the operation. CAUTION The minimum pumped volume is shown in the performance diagram of the pump (smallest shown Q value).

ALLWEILER

13

7.3.4 Temperature Any sudden temperature changes (temperature shocks must be avoided).

7.3.5 Higher density of pumped media Where the density of the pumped media is higher than that stated in the order information (i.e. larger than the value on which the design of the pump was based), the performance data of the pump is reduced whilst the performance requirement is increased. It must be observed that the motor is not being over-loaded.

7.3.6 Increased pumping volume CAUTION Where a higher pumping volume is produced than specified in the order and design data, it must be observed that the existing feed height still suffices (condition: NPSHexist. < NPSHact.) as other cavitation and other adverse effects may occur. Where the pump is used as a boiler feed pump, it must be observed that the pump is not used for a smaller operating pressure than the intended one. Where the feed boiler is periodically operated at a lower operating pressure, the pump must be throttled to the standard operating pressure of the boiler, us-ing the manual shut-off valve and a pressure gauge installed on the delivery section of the pump housing.

7.3.7 Switching frequency The pump may be switched on and off up to ten times per hour.

7.4 Switch-off and restart 7.4.1 Switch-off

Prior to the standstill of the pump no shut-off units may be closed on the delivery and suction side. Switch off motor. Check that pump drains off evenly. In case of an in-stalled return valve, shut-off units do not have to be closed. In case of longer standstill and excess pressure on the suction side (feed) the shut-off fitting on the suc-tion side must be closed. Any auxiliary equipment (sealing liquid, etc.) must be switched off. For pumps where the pumping media is under vac-uum, it must be checked that still sufficient operating media is in the pump prior to restarting. Fill pump if necessary. Where the pump remains under pressure and tem-perature even when in standstill mode, all existing shut-off pipes must remain activated. Shut-off de-vices must remain activated, if there is a danger of air being sucked in (in case of feed from vacuum sys-tems or in case of parallel operation with mutual suc-tion pipe). In case of possible frost, fully drain pump and pipes.

7.4.2 Restart

It must be checked whether the pump shaft is stand-ing still. In case of a leaking return valve in the deliv-ery pipe, it may occur that the pump shaft is turned backwards by reflowing pump media. The pump may not be switched on whilst the pump shaft is turning backwards as this may damage the pump.

7.5 Measures in case of longer standstill Where pumps are stored for a longer period prior to installation, pumps must be protected against humid-ity and moisture, (i.e. by packing in oil paper and plastic foil!). For other measures see Section 3.7 Storage and monitoring preservation. In case of the pump being stored, the suction and delivery section and all other feed and drain sections must be closed with blank flanges or stoppers. Dur-ing storage, the pump must be at least turned once a month (do not switch on, to prevent dry running). The rotational position of parts such as shafts and ball bearings should be changed at the same time. Where necessary, unblock by slightly tapping the shaft in actual direction. After a maximum of four years, replace bearing as the grease will be unus-able due to ageing. CAUTION In case of longer standstill periods, the pump must be filled with suitable preservation agent. In case of a possible exposure to frost, the pump, the shut-off circuit, etc. must be protected against freezing or drained and preserved.

8. Maintenance 8.1 Safety measures

!

For any maintenance and servicing, the informa-tion provided in Section 2. Safety must be ob-served. Regularly implemented inspection and maintenance work carried out on the pump and the drive machine will prolong the life of the units.

8.2 General control ● The pump may never be operated without pump-

ing media or with the flow of the pumping media being disrupted. Check the fluid level in the suc-tion and/or feed container.

● The minimum supply volume must be maintained. ● Control speed and lift. ● The drive motor may not be overloaded. ● The pumps and units should always run quietly

and free from vibration. All suction-sided shut-off units, filters must be kept fully opened.

● Pressure and temperature monitoring equipment

as well as flow equipment must be monitored.

ALLWEILER

14

● Installed stand-by pumps should be switched on and off again once a week.

8.3 Maintenance of components 8.3.1 Storage and lubrication

External rolling bearing are permanently filled with grease. These closed bearings cannot and do not have to be lubricated. The temperature of the bear-ings may not exceed 80°C. In case of the correct op-eration of the pump, bearings only have to be changed for the first time after approx. 10,000 oper-ating hours. Also, internal carbon sliding bearings must be changed after this operating period. Where any access temperature is being detected, this indi-cates a damaged bearing and the deep groove ball bearing should be replaced as soon as possible (see Section 9. Servicing).

8.3.2 Flexible coupling The condition of the flexible element in the coupling should be regularly checked. Note: Used flexible elements should be replaced. After approx. 1,000 operating hours, the distance between the two cou-pling halves should be checked for the first time (see Section 6.3.6 Checking the flexible coupling). The rubber coupling packages used in the claw couplings must be checked. In case of heavy wear, it must be assumed that the motor is not aligned with the pump or that the distance between the coupling sections has changed. In most cases this will cause bearing damage in the pump.

8.3.3 Drive See Operating Instructions of the drive motor manu-facturer.

8.3.4 Stuffing box packing Stuffing box packing is constantly serviced. In order to increase the life of the stuffing box packing, the packing must be accurately monitored and adjusted during the first operating hours. The stuffing box packing should drip slightly during operation. In order to prevent the unit from running dry, the plant and/or nut should be loosened where necessary. Stuffing boxes should only be tightened to such an extent that a small leak of approx. 60 drops per min-ute can still escape (stuffing box lubrication!). Dry-running packaging hardens, overheats and de-stroys the shaft. In case of longer operating periods and frequent retightening of the stuffing box rings, an additional stuffing ring can be inserted. After an op-erating time of approx. 4,000 to 5,000 hours and a deformation of the packing rings by more than 25%, the entire shaft seal should be repackaged.

!

Due to the resulting injury hazard, pumps may under no circumstance be repackaged during operation.

8.3.5 Axial face seals Axial face seals are maintenance-free but are only free from leakage to a certain extent. During opera-tion it must be observed that the axial face seals never run dry and that the conditions of use are within the application limits of the selected axial face seals. A leakage of approx. 2.5 cm3 per hour is ac-ceptable. In case of a leaking axial face seal, this cannot be re-tightened; it is therefore recommended to remove and check the axial face seal and shaft as well as any ancillary elements. As the life of the axial face seals can normally not be estimated, we recommend to store replacement seals.

9. Servicing, disassembly and reassembly 9.1 Safety regulations

!

As repairs are carried out by our own personnel or by specialised installers, it must be ensured that the pump is completely emptied and clean. This applies, in particular, for pumps that are sent to our works or a contractual agent for re-pair. For the protection of our employees and for environ-mental reasons, we are not able to accept pumps filled with pumping media for repair. Custom-ers/operators must otherwise pay for the cost of the correct disposal. In case of pumps operated with hazardous materials and/or media dangerous to the environment, the cus-tomer/operator must, on his own accord, inform our own or the installation personnel on site or our works or repair shop. In this case, a certificate for the pumped media, for instance in form of a DIN safety sheet, must be provided upon requesting a customer service fitter. In case of any on site work, the user’s and/or our service personnel must be made aware of any haz-ards that may arise in connection with the repairs. These instructions contain a description of the main disassembly and assembly steps. The assembly steps described in the individual sections must be adhered to.

9.2 Dismantling information ● During the guarantee period, the pump may only

be disassembled by ourselves or by an author-ised workshop.

● Outside of the guarantee period, the pump may

only be dismantled and installed by experienced personnel.

Prior to the start of the assembly, the unit must be secured in such a way that it cannot be switched on.

ALLWEILER

15

!

The pump housing must be depressurised and empty.

!

All shut-off units in the suction, feed and delivery pipes must be closed.

!

All parts must have attained ambient tempera-ture.

!

Remove pump from motor, base plate and pipes prior to repair.

9.3 Motor repairs

Electrical repairs may only be carried out by a qualified electrician.

9.4 Disassembly

CAUTION The position of the individual housing parts must be marked prior to the disassembly to ensure that they can be reassembled in the cor-rect order (i.e. by chalk markings).

Detailed disassembly and reassembly instruc-tions can be provided on request. Please contact: see last page

ALLWEILER

16

10. Faults, causes and remedies 10.1 Safety regulations

!

Faults may only be remedied by trained personnel. In case of faults, pump must be switched off as soon as possible!

10.2 Faults and remedy

Faults Cause Remedy

● Counter pressure too high Readjust operating point ● Lift too high or feed height too low Check fluid level, open suction-side

shut-off units ● Blocked filter ● NPSH not observed

Clean filters and dirt pans installed on the suction side

● Sealing gap too large due to wear Replace worn pump components ● Incorrect direction of rotation or

speed Reconnect motor

Pumping volume too low

● Housing or suction pipe leaking Replace housing seals. Check flange connections

● Suction pipe or suction-side shaft seal leaking

Replace housing seals. Check flange connections

● Lift too high Check fluid levels ● Gap between impeller and stage too

large Replace worn pump components

● Incorrect direction of rotation Reconnect motor ● Liquid volume in pump too low Refill pump! ● Suction or pressure slider closed Open all shut-off units! ● Incorrect pipe connection Reconnect pump ● Incorrect electrical connection Reconnect motor ● NPSH not observed Clean filters and dirt pans installed on

the suction side

Pump not sucking

● Closing stopper not removed Remove closing stoppers ● Housing fixing leaking Check securing torque of housing bolts Leaking pump ● Defective seals Replace seals ● Pump or pipe not fully filled Vent and fill pump as well as suc-

tion/supply line ● Suction lift too high and/or delivery

lift too low Check fluid levels, open suction-sided closing units

Temperature increase in pump

● Pump is running dry Clean the filters and dirt pans installed on the suction side

● Pump or pipe not completely filled Vent and fill pump as well as suction and/or feed pipe

● Suction lift too high and/or delivery lift too low (cavitation)

Check fluid levels, open suction-sided shut-off units

● Q-min. is not reached Clean filter and dirt pans installed on suction site

● Pump is not installed level on floor or is twisted

Check installation of pumps

Pump runs unevenly or noisily

● Foreign bodies in pump Disassemble and clean pump ● Foreign bodies in pump Disassemble pump and replace dam-

aged parts ● Closed slider in pressure pipe Open shut-off units ● The permitted pumping conditions

were not complied with Observe the pumping conditions speci-fied in the datasheet

● Power take-up greater than set upper limit

Check the motor protection switches and the electrical connections

Motor protection switch cuts out

● Increased friction in pump Check: ● whether the pump is blocked by

foreign bodies ● stuffing box is tightened too much ● shaft seal is OK

ALLWEILER

17

11. Ancillary documentation 11.1 Impeller gap dimensions

Pump material types 10, 12, 22 with flat seals (tmax. = 120°C).

Pump series Impeller widths Depth of pres-sure side

Thickness of seal Total gap Gap on each

side 100/110 10 – 0.02 9.98 + 0.02 0.15 + 0.02 0.13 + 0.06 0.065 + 0.03

210/220/330 10 – 0.02 9.98 + 0.02 0.15 + 0.02 0.13 + 0.06 0.065 + 0.03 440 14 – 0.02 13.98 + 0.02 0.17 + 0.02 0.15 + 0.06 0.075 + 0.03 550 19 – 0.04 19.01 + 0.04 0.17 + 0.02 0.18 + 0.10 0.09 + 0.05 660 22 – 0.04 22.01 + 0.04 0.17 + 0.05 0.18 + 0.13 0.09 + 0.065

Pump material type 32 with PTFE round seals (tmax. = 120°C).

Pump series Impeller widths Depth of pres-sure side Thickness of seal Total gap Gap on each

side 100/110 10 – 0.02 10.15 + 0.02 0.03 0.18 + 0.04 0.09 + 0.02

210/220/330 10 – 0.02 10.15 + 0.02 0.03 0.18 + 0.04 0.09 + 0.02 440 14 – 0.02 14.18 + 0.02 0.03 0.19 + 0.04 0.095 + 0.02 550 19 – 0.04 19.18 + 0.04 0.03 0.21 + 0.08 0.105 + 0.04 660 22 – 0.04 22.18 + 0.04 0.03 0.21 + 0.08 0.105 + 0.04

Pump material type 10, 12, 22 with PTFE T-type flat seals (tmax. = 140°C).

Pump series Impeller widths Depth of pres-sure side Thickness of seal Total gap Gap on each

side 100/110 10 – 0.02 10.04 + 0.02 0.15 + 0.02 0.19 + 0.06 0.095 + 0.03

210/220/330 10 – 0.02 10.07 + 0.02 0.15 + 0.02 0.22 + 0.06 0.11 + 0.03 440 14 – 0.02 14.07 + 0.02 0.17 + 0.02 0.24 + 0.06 0.12 + 0.03 550 19 – 0.04 19.14 + 0.04 0.17 + 0.02 0.31 + 0.01 0.155 + 0.05 660 22 – 0.04 22.16 + 0.04 0.17 + 0.05 0.33 + 0.13 0.165 + 0.065

Pump material type 32 with PTFE, T-type round seals (tmax. = 140°C).

Pump series Impeller widths Depth of pres-sure side Thickness of seal Total gap Gap on each

side 100/110 10 – 0.02 10.21 + 0.02 0.03 0.24 + 0.04 0.12 + 0.02

210/220/330 10 – 0.02 10.24 + 0.02 0.03 0.27+ 0.04 0.135 + 0.02 440 14 – 0.02 14.25 + 0.02 0.03 0.28 + 0.04 0.14 + 0.02 550 19 – 0.04 19.31 + 0.04 0.03 0.34 + 0.08 0.17 + 0.04 660 22 – 0.04 22.33 + 0.04 0.03 0.36 + 0.08 0.18 + 0.04

Contents of Appendix: 11.2 Sectional diagram of pump 11.3 Sectional diagram of shaft seal 11.4 Datasheet

The technical specifications of the pump are contained in the datasheet. The dimensions are contained in the dimen-sional table which can be supplied on request.

12. Identification

The pumps contain a nameplate according to DIN 24299 as shown in Fig. 12.1.

Fig. 12.1

ALLWEILER

18

11.2 Cross-section of pump SON…WW

SON…W

SRN…WW

ALLWEILER

19

SOB…W

SRB…WW

SOV…W/SRV…W single stage SOB…W/SRV…W multi-stage

ALLWEILER

20

11.3 Sectional drawing of shaft seal Sliding ring type

Stuffing box type

Part no. Designation Part no. Designation 1 delivery housing 26 stuffing box 2 suction housing 27 union nut 3 suction section 28 curved washer 4 delivery side 29 washer 5 suction side 30 shaft nut 6 impeller 31 stopper 7 shaft 33 connecting bolt with nut 8 double footstand 34 bypass 9 foot lantern 35 pipe fixing 10 bearing support 36 locking ring 11 rolling bearing 41 coupling half, pump side 12 bearing lid 42 coupling half, motor side 13 end bearing lid 43 coupling packages 14 spacer ring 51 counter flange 16 bearing bushing, long 52 flange seal 17 bearing bushing, short 53 hexagonal screw 18 cheese-head screw 61 axial face seal 21 splash ring 62 counter ring 22 sealing ring, white 63 flat backing 23 sealing ring, narrow 64 circlip ring 24 packing ring 65 set collar

ALLWEILER

Subject to technical alterations

ALLWEILER Radolfzell Works Postfach 1140 D–78301 Radolfzell Allweilerstrasse 1 D–78315 Radolfzell Germany Phone (07732) 86 0 Fax (07732) 86 436 E-mail: service@allweiler.de internet: http://www.allweiler.de