Circulating pumps Model ZHT / ZHB / ZHS / TH / THK / DUO-ZHB,-ZHS,-TH,-THK... · Circulating pumps...

2722

4 - B

.1

Circulating pumps

Model ZHT / ZHB / ZHS / TH / THK / DUO

Operator´s manualGB

Schmalenberger GmbH + Co. KG D-72072 Tübingen / Germany

EG-KonformitätserklärungDéclaration de conformité pour la CEE / EC-Declaration of Conformity /

CEE-Certificado de Conformidad / Dichiarazione CE di conformità

Hersteller / fabricant / manufacturer / fabricantee / fabrikantSchmalenberger GmbH+Co KGStrömungstechnologieIm Schelmen 9-11D-72072 Tübingen / Germany

Produkt / produit / product / producto / prodottoKreiselpumpen / Pompes centrifuges / Circulating pumps / Bombas centrifugas / Pompe centrifughe

Typ / modèle / model / modelo / tipoZHT, ZHB, ZHS, TH, THK, DUO, ZHR, DMG

Hiermit erklären wir, dass die spezifische Bauart in Übereinstimmung mit den folgenden Richtlinien hergestellt worden ist:Par la présente, nous declarons, que le type de est produit conforme aux dispositions des directives européenne sci après:We hereby declare that the specific type has been produced in accordance with the following standards:Por la presente les confirmamos que lo abajo especificado ha sido fabrico en conformidad con las siguientes normas:Si dichiara che il modello della è stato in conformità alle sequenti norme:

EG - Richtlinien / Directives de la CEE / EEC Directives / Normativas de la CEE / Direttive CEE• 2006/42/EG• 2006/95/EG• 2004/108/EG

Zur sachgerechten Umsetzung der in der EG-Richtlinie genannten Sicherheits- und Gesundheitsanforderungen wurde(n) fol-gende Norm(en) herangezogen:Pour mettre en partique dans les règles de l'art les prescritions en matière de sécurité et de santé stipulées dans les Directives de la CEE, il a été tenu compte de la /des norme(s):For the relevant implementation of the safety and health requirements mentioned in the Directives, the following standard(s) must be required:Con el fin de realizar de forma adecuada las exigencias referentes a la seguridad y a la snidad mencionadas en las norma-tivas de la CEE fuè(ron) consultada(s) la(s) siguiente(s) normativa(s):Per la verifica della Conformità di cui alle Direttive sopra menzionate, sono state consultate le seguenti, norme Armonizzate EN:

Harmonisierte Normen / Normes harmonisées / Harmonised Standards / Normas armonizadas / Norme armonizzateEN ISO 12100-1, EN ISO 12100-2, EN 61000-6-2, EN 61000-6-3, EN 809, EN ISO 14121-1

Tübingen, den 21. Dezember 2009

-------------------------------------------------------------------------------------------------Leiter Qualitätssicherung / Directeur d’assurance de la qualité /

Manager of quality assurance / Director del assegunamiento de qalidad /Direzione qualità / Tel. +49(0)7071 7008-18

3Pumpe Typ ZH-/TH-/DUOVersion: 27224 - B

Schmalenberger GmbH + Co. KGD-72072 Tübingen / Germany

4 Pumpe Typ ZH- / TH- / DUOVersion: 27224 - B


Contents1 General Details................................................................................................ 51.1 User Information .............................................................................................................. 51.2 Usage Instructions ........................................................................................................... 51.3 Relevant Documentation.................................................................................................. 51.4 Technical Data / Specifications........................................................................................ 5

2 Safety Instructions ......................................................................................... 52.1 General ............................................................................................................................ 52.2 Temperature .................................................................................................................... 62.3 Safety Instructions for Maintenance and Repairs ............................................................ 6

3 Description of the types of pump.................................................................. 73.1 General Description ......................................................................................................... 7

4 Transport, Storage, Installation..................................................................... 84.1 Transport and Storage ..................................................................................................... 84.2 Unpacking, Cleaning and Assembling ............................................................................. 94.3 Installing and connecting ................................................................................................. 9

5 Pump operation .............................................................................................. 125.1 Initial start-up ................................................................................................................... 125.2 Operating ......................................................................................................................... 125.3 Indications of faulty operation .......................................................................................... 135.4 Shutdown ......................................................................................................................... 145.5 Fault elimination............................................................................................................... 15

6 Maintenance / Repair...................................................................................... 176.1 Maintenance / Service ..................................................................................................... 176.2 Repair .............................................................................................................................. 176.3 Spare parts list / Drawing................................................................................................. 21

7 Appendix ......................................................................................................... 217.1 Shutdown / Storage / Conservation ................................................................................. 217.2 Disposal ........................................................................................................................... 227.3 Supporting documents for pump operation...................................................................... 227.4 Data sheet........................................................................................................................ 227.5 Important Instructions ...................................................................................................... 23

8 Spare parts list and drawing..........................................................................24ZHT................................................................................................................................. 25ZHS................................................................................................................................. 26ZHB................................................................................................................................. 27TH / THK ......................................................................................................................... 28DUO ................................................................................................................................ 29ZH / ZHS / ZHB with additional second pressure outlet.................................................. 31ZHT with elongated immersion depth ............................................................................. 32ZH-...L ............................................................................................................................. 33

8.1 Spare parts list ................................................................................................................ 34


Pumpe Typ ZH- / TH- / DUOVersion: 27224 - B

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1 General Details1.1 User InformationThis operator’s manual makes it easier to get toknow the centrifugal pump and to make full useof its facilities.The operator’s manual contains importantinstructions how to use the centrifugal pumpsafely, properly and economically. The operator’s manual does not take account oflocal regulations. The user is responsible forensuring that they are complied with.The label specifies the machine series, theframe size, the most important operating dataand the serial number. We request that youalways quote it in case of queries, when placingsubsequent orders and especially whenordering spare parts.

1.2 Usage InstructionsThe centrifugal pump must only be used inaccordance with the original pumpspecifications and the operator´s manual.Any other usage or operation where thesefigures are exceeded is not permitted. Themanufacturer is not liable for damage resultingfrom such improper use.

1.3 Relevant DocumentationVarious documents are associated with everycentrifugal pump that comprise the technicaldocumentation of the pump. These are asfollows:• Operator’s manual• Drive operator’s manual• Manual for accessories listed in the

specifications manual• Acceptance report from the TÜV (Technical

Certification Authority) etc.• Pilot run report• Performance run report• Installation drawing (dimensions sheet)• Declaration of conformity with supplement

BA for Ex-model in accordance with thedirective 94 / 9 / EG (Atex 95)

• Conformity statement / manufacturer’sdeclaration

• Specification with all data

Not all the above documentation has beenproduced and supplied in every case. For thisplease check the details in the specification.

1.4 Technical Data /Specifications

The specifications of the centrifugal pump is themost important document in every operator’smanual. Contained therein are all the relevantand technical data relating to the centrifugalpump. It is the birth certificate of the centrifugalpump and should be treated accordingly.As a substitute the order confirmation togetherwith the delivery schedule may also be a sourceof technical data.

2 Safety Instructions2.1 GeneralIt is essential that the relevant safety regulationsand laws that apply in the operating companyand / or country where the pumps are to be usedare observed .

In this operating manual the following symbolsare used to draw your attention to sources ofdanger. The symbols are intended to attract yourattention to these instructions!Symbol Meaning:

Notices attached directly to the pump, e.g.arrows indicating direction of rotation and themarking for fluid connections, must always beobserved and maintained in a clearly legiblecondition.

Attention! Danger of injury!This sign warns you of the dangerof mechanical effects.

Warning! Mortal danger!This sign warns you of the dangerfrom electric shocks.

Information:It also instructs you in the economicuse of the pump.



- Use the pump only if it is in perfect technicalcondition, in accordance with the regulations,observing safety requirements and dangerconditions and strictly adhering to all the in-structions in the operator’s manual!

- Promptly remedy any faults that could influ-ence safety.

- Prior to starting up, make sure that theoperators have read and understood theoperator’s manual. Not the operator but theowner is responsible for safety!

- The centrifugal pump is designed to be builtinto a total machine or plant. The centrifugalpump is delivered without any protectionagainst accidental contact. If necessary, thesystem supplier must fit appropriate protectivecovers in integrating the centrifugal pump intothe plant (e.g. if hot liquids with a temperatureover 60° C are delivered).

- Leaks of hazardous delivery media, (e.g. ex-plosive, poisonous, hot) must be controlled sothat no danger occurs to persons or the envi-ronment. Comply with legal requirements.

- Danger from electric shocks must be comple-tely excluded (for details see the country spe-cific regulations and / or those of the localpower supply company).

- Electrical equipment must be installed andmaintained exclusively by qualified electrici-ans in accordance with regulations VDE orIEC.

- Before switching on or starting up the centrifu-gal pump, make sure that no-one will beendangered by the start-up of the pump!

2.2 Temperature

2.3 Safety Instructions for Maintenance and Repairs

- Regardless of what nature they may be, re-pairs must only be carried out by qualified per-sons and the centrifugal pump must beemptied first.

- The attached pipework must be depressuri-zed.

- Allow the pump to cool off.- Prior to carrying out repairs to the pump it

must be isolated from the electrical supply andprotected from unintentional switching on.

Important:The centrifugal pump must beimmediately stopped if abnormalelectrical voltages, temperatures,noises, vibrations, leakages orother faults should arise.

Warning! / Danger of burns!The centrifugal pump housing getshot during operation. If thetemperature rises to over +50°C,the centrifugal pump must beprotected from direct contact by theoperator.



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3 Description of the types of pump

3.1 General Description

Depending on their field of usage, differentpumps are offered. In the following overview, thetypes within the range are described.

Type ZHT- Multi-stage submersible pump with block motor- Vertical container installation due to support plate- Shaft seal as mechanical seal- Axial suction connection

Type ZHS- Multi-stage submersible pump with block motor- Vertical installation with suction stand- Shaft seal as mechanical seal- Radial suction connection

Type ZHB - Multi-stage centrifugal pump with block motor- Horizontal installation- Shaft seal as mechanical seal- Axial suction connection- Special model with dry-run-protection / catchment

chamberType TH / THK

- Multi-stage submersible pump with block motor- Vertical container installation to DIN EN 12157- Shaft seal as mechanical seal- Axial suction connection- THK = Plastic model

Type DUO- Two multi-stage submersible pumps with block motor

in series- Vertical container installation due to support plate- Shaft seal as mechanical seal- Axial suction connection

Type ZH (T,S) -L- Multi-stage submersible pump with bearing pedestal- Vertical installation like ZHT and ZHS but with

coupling and Norm-motor



4 Transport, Storage, Installation

4.1 Transport and Storage4.1.1 TransportCentrifugal pumps must be transported lyingdown! The eyebolts on the motor are designedto carry only the weight of the motor. To lift thecombined motor and pump aggregate suitableattachments must be made so that both unitsare catered for! If necessary the centre of mass is indicated onthe pump aggregate itself and on the packingmaterial and places for applying hooks aremarked.

Proper lifting example ZHS

Proper lifting example ZHB

Proper lifting example ZHT

Proper lifting example TH / THK

4.1.2 Storage- Interim storageEven for short periods of interim storage, storeon a wooden base in a dry, well ventilated andvibration free environment at constanttemperature.

- Unsuitable storageIf unsuitable storage conditions prevail (e.g. highhumidity) or if the pump is to be stored for longerthan 6 weeks, then the pump housing should befilled with oil (see 4.1.3).

- Long periods of storageAfter a storage period of more than 2 years themotor roller bearings and bearing supports needto be re-greased or replaced entirely.

4.1.3 ConservationThe centrifugal pumps that we deliver aretreated with a conservation materialcorresponding to the storage time quoted us bythe purchaser. This conservation must beremoved before start-up. See chapter 4.2.2"Cleaning". If the pump is to be taken out ofservice for a longer period of time or if theoriginally envisaged storage time is going to beconsiderably exceeded, then conservation mustbe undertaken as protection against corrosion.For a detailed description of how to proceedunder these circumstances, see chapter 7.1"Shutdown / Storage / Conservation".

Warning! Risk of injury!Use only suitable and technicallyperfect lifting and load-bearingequipment with sufficient carryingpower!Never stand or work underneathswinging loads.



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4.2 Unpacking, Cleaning andAssembling

4.2.1 UnpackingFor transportation purposes the pump isfastened to a palette by bands. Fortransportation over long distances it is packed incrates or boxes . After removing the retainingbands extract the pump out of its packing withthe help of suitable lifting equipment. Be sure toobserve the instructions under 4.1.1.

4.2.2 CleaningA number of measures are taken for protectionagainst transportation damage and corrosion.Check your pump for which measures havebeen taken.1. Covering lid on the nozzles2. Shaft protection for deliveries without the

motor3. Protective paint on exposed partsThese protective measures must be removedbefore the pump is set up or installed. Under no circumstances must impurities be leftinside the pump .

4.2.3 AssemblyIn general the pump is delivered fully assembledand can be installed directly.In special cases the pump is delivered withoutthe drive motor. Prior to installing it in the plant,fit the drive to the pump.

Other external accessories such as a blast tankor similar equipment that has not been pre-assembled with the pump at the factory, shouldbe fitted to the pump after it has been installed inthe system or on the pump base.

4.3 Installing and connecting4.3.1 Safety requirements

Important:Depending on the delivery mediumto be used, the interior of the pumpshould be cleaned of residualtraces of oil. Use a cleaning agentthat will not be harmful to themechanical seal and the pumpmaterials. Make sure that the pumpis carefully dried after cleaning.The cleaning agents that can beused include spirit, Ritzol 155 or astrongly alkaline soap solution, forexample. If a steam jet cleaner is tobe used, then let the solvent workitself in for a time first.Please do not use a steam jetcleaner. If this is unavoidable, thenplease take care not to damage theelectric motor and bearings.

Important:Before installation check that thepump runs freely and easily.

Explosion proof / safety instructionsElectrical appliances that areoperated in areas where there is adanger of explosion, must complywith the explosion proofrequirements. This is stated on thefactory plate of the motor. Forinstallations in areas where there isa danger of explosion, the localexplosion regulations and those onthe test certificate supplied with thedelivery, and which was issued bythe responsible inspectionauthority, must be observed. Thetest certificate supplied must bekept at the installation location (e.g.the master’s office).

Important:For areas where there is adanger of explosioninaccordance with directive 94/9EG (Atex 95), please observe thesupplementary operatinginstructions.



4.3.2 Check before you startinstalling

• Have the machine, the system and thecontainer nozzles been properly prepared inaccordance with the figures on thedimensions sheet or installation plan?

• Has the concrete base got adequatestrength in accordance with DIN 1045?

• Is the concrete base hydrated?• Is the surface level and even?

4.3.3 Pump installation and removalCentrifugal pumps type "ZHB" may only beinstalled horizontally, those of type "ZHS" mayonly be installed vertically.Apart from certain special models, the pumpsare always equipped with a pump or motor foot(ZHB) or with a pump stand (ZHS) and must beplaced on a base plate and fastened down withscrews.When installed on a foundation the pump mustbe set up with the aid of a spirit level.Centrifugal pumps type "ZHT, TH, DUO" mayonly be installed in a vertical position.Apart from certain special models, these pumpsare always placed on the cover plate or theflange and fastened down with screws.

4.3.4 Connecting the pipework

Warning! Static stability,Risk of injury!Pumps with large drives that aremounted vertically are top heavy.These pumps must be safeguardedagainst tipping up duringinstallation or removal e.g. with thehelp of ropes.

Warning!Under no circumstances mustthe pump be used as anchorpoint for the pipework. No forcesor moments (e.g. due to twistingor heat expansion) from thepipework must act on the pump.

The pipes must be supported asclose as possible to the centrifugalpump and connected to it free of alltension. Their weight must not besupported by the pump.The positioning must beundertaken with the greatest careas this is the prerequisite fortrouble-free operation of the plant. If these instructions are notobserved, then any claims underguarantee will be void.

Warning!In the case of hot, caustic orpoisonous delivery media!If the pipe strength is exceededleaks can occur in the pump or inthe flange connections, forexample, that could result in vastamounts of medium beingexpelled.In the case of short pipes thenominal bore should be at least thesame as the centrifugal pumpconnections. For long pipes themost economic nominal boreshould be determined on a case bycase basis.Connection pieces to largernominal bores should be carriedout with approx. 8° expansionangle to avoid significant loss ofpressure.In order to prevent the formation ofair pockets, the suction pipe to thecentrifugal pump must be installedto rise continuously, on thepressure side it must fallcontinuously. Depending on thetype of system and centrifugalpump being used, it isrecommended that backflowprevention and shut-off devices areinstalled.



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4.3.5 Electrical connectionsThe electrical connections to the pump must becarried out by a specialised company in theelectrical engineering branch approved by thelocal energy provider, taking into account thetechnical connection requirements. Theconnections must be carried out by a qualifiedelectrician. (see 4.3.1)

The relevant DIN VDE (Association of GermanEngineers) regulations must be observed.Compare the available mains voltage with thedetails on the motor’s factory plate and selectthe appropriate switching.We recommend the use of a motor protectionfacility.

Connect the motor in accordance with the circuitdiagram in the terminal box or according to thefigures showing delta or star connections.

Delta connection ��lower voltage)

Connection diagram for 3-phase motors,Circuit arrangement �

Star connection Y (high voltage)

Connection diagram for 3-phase motors,Circuit arrangement Y

Time relay settingFor three-phase motors with star-deltaconnection it must be ensured that the switchingpoints between star and delta follow each othervery rapidly. Long switching times can result indamage to the motor. Setting of the time relayfor star-delta connection: 3 to 5 secondsdepending on the motor performance.

Expansion of the pipes due totemperature must be remedied bysuitable measures. We recommend the installation ofcompensators immediatelybetween the pump and the pipes.

Warning! Mortal danger!Taps that close very suddenly(abruptly) must be avoided in thepipework. The resulting pressuresurges can greatly exceed themaximum permitted housingpressure of the pump! To prevent too strong pressuresurges dampers or blast tanksshould be installed.

Note:At the end of installation, beforestarting up the system thecontainers, pipes and connectionsmust be thoroughly cleaned, rinsedand blown through.Often welding beads, scales andother impurities do not getdislodged for some period of time.The should be kept clear of thepump by inserting a sieve in thesuction pipe.The free cross-section of the sievemust be 3 times the cross-sectionof the pipe so that there is not toolarge a resistance built up due toforeign bodies that flow in.Hat-shaped sieves containing amesh wire net having a mesh sizeof 2.0 mm and 0.5 mm wirediameter made of corrosionresistant material have proveduseful in practice.

Risk of explosion!Where there is a risk of explosion amotor protection device must befitted!

Motor performance � 30kW 3sec ±30%Motor performance > 30kW 5sec ±30%

W2 U2 V2

U1 V1 W1L1 L2 L3

W2 U2

U1 V1 W1L1 L2 L3

V2



Direction of rotation checkThe direction of rotation of the motor must agreewith the direction of the rotation arrow on thespiral housing of the pump. Check by rapidlyswitching on and off.If the direction of rotation is wrong, change anytwo phases L1, L2 or L3 of the power supply inthe motor terminal box over.

Additional motor equipmentIf particular control devices are to be used e.g. inconnection with the installation of the pump in aprocess engineering facility, the instructions ofthe manufacturer of the control device must bestrictly observed.

5 Pump operation5.1 Initial start-up

5.1.1 Starting the pumpOnly switch the pump on when the shut-offdevice on the pressure side is closed! Once themaximum rotation speed has been reached,slowly open it up and adjust to full operationallevel.• An automatic backflow prevention device

must constantly open once the operationalvalue has been reached without theproduction of abnormal noises, vibrations orincreased current consumption in the plant.

• Once the operating point has been reached,the power input to the motor and the bearingtemperature must be monitored! When firststarted up the ultimate bearing temperatureis attained only after about 48 hours,depending on ambient conditions.

5.2 Operating5.2.1 Operation monitoringIn most cases the centrifugal pump is controlledfrom the central point of the overall facility. Aprerequisite for a perfectly functioningcentrifugal pump is adherence to the dataprovided for its installation and use. See thechapter on specifications.

1. Temperature of the delivery fluidNever operate the pump at temperatures inexcess of those stated in the originalspecification.

Prior to initially starting up thecentrifugal pump please make surethat the following prerequisiteshave been met:1. The centrifugal pump has been

connected properly electricallyand with all requisite safetyfeatures.

2. The pump is completely filledwith delivery medium or thatthe minimum level of fluid ispresent in the tank / pool (thepump is covered) and thatfurther supply is available.Please observe: Dry runningleads to increased wear anddamage to the pump!

3. On the suction side all shut-offdevices are open and thesuction pipe is vented.

4. The rotating parts of the pumphave been covered by aprotective shield. (Inaccordance with UVV(Accident PreventionRegulations) the centrifugalpump may only be operated if asafety shield has been fitted).

5. It has been checked that thepump shaft rotates easily(observe the instructions under4.2.3 )

6. The direction of rotation hasbeen checked.

7. There is a minimum distancebetween the suction inlet andthe tank wall of 150 mm.

Pay particular attention to thefollowing points for the manualoperation of the centrifugal pump:



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2. Switching frequencyIn order to avoid a large temperature increase inthe motor and excessive strain on the pump,motor and bearings the switching frequencymust not exceed the following guideline figures.

3. Minimum amountIf the sort of facility includes the possibility of arun against closed shut-off device on thepressure-end, a minimum delivery rate at t -30 to+70°C 15% of Qopt. must be supplied duringthis time. Over +70 to +110°C it must be 25% ofQopt.

4. Density of the delivery fluid The power input of the pump changes inproportion to the density of the delivery fluid. Toprevent the motor being overloaded, the densitymust correspond to the data in thespecifications.

5. Mechanical sealThe sealing unit has been fitted and set at thefactory. The gasket is maintenance free butshould be checked for leaks from time to time.During initial start up there may be increasedleakage for a brief time. If increased leakagepersists then the plant should be switched off atonce and the cause determined. The causecould be dirty medium or a prior period of dryrunning through incomplete venting of the pump,for example.

5.2.2 MiscellaneousInstalled reserve pumps must be run briefly oncea week to ensure that they are always ready foroperation. They should be run each time forapprox. 10 minutes. This also applies to anypump that is not in use but must remain ready foroperation.

5.3 Indications of faulty operation5.3.1 GeneralWhen operated via a central control facility faultyoperation can be largely ruled out.In the case of manual operation, but also withina control complex, please make sure that:• The pump always runs quietly and vibration

free.• The pump does not run dry.• A longer period of operation with closed

shut-off device is avoided to prevent heatingup the delivery medium. For the requisiteminimum delivery quantity see chapter5.2.1.

• The maximum permitted room temperatureof +40°C is not exceeded.

• The ball bearing temperature does notexceed the room temperature by more than+ 50ºC and in any event does not exceed +90ºC overall (measured at the exterior of themotor housing).

• During centrifugal pump operation the shut-off device in the supply line is not closed.

5.3.2 FaultsIn case of faults in the operation of thecentrifugal pump, that were not caused by thecontrol facility or other foreign devices, proceedas follows:1. Locate the site of the fault or defect.2. Determine the cause.3. Remedy the fault.

In chapter 5.5 "Fault elimination" there is a tablelisting the most frequent faults, their cause andthe recommended way to eliminate them.

Motor power: Max. no. switches / hup to 3 kW 20from 4 to 11 kW 15from 11 to 45 kW 10



5.4 Shutdown1. Close shut-off device in the pressure and

suction pipes. If backflow prevention is fittedto the pressure pipe the shut-off device canremain open, provided that there is backpressure.

2. Switch motor off. Allow it to come to rest.Depending on the sort of facility, the pumpshould be allowed sufficient idle run time –with the heat source, if any, switched off toallow the delivery fluid temperature toreduce – to prevent an accumulation of heatwithin the pump.

3. Close the shut-off device in the suction pipe. Warning! Risk of damage!If there is a danger that the pumpmay freeze and / or for occasionswhere it is to be at a standstill forlonger periods of time, the pumpmust be emptied or protectedagainst freezing up (by auxiliaryheating).



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5.5 Fault elimination

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x x x Counter-pressure too high, pump working against too much pressure, plant resistance too high, performance too low

Reset operating point, clean the plant out, increase the rpm, install a new impeller, clean the pipes, enlarge the pipes, use a larger pump

x x x Pump / pipework not completely vented, air being sucked in due to too little covering, gas production, air pockets in the pipes, high level of air content in the medium, supply or impeller blocked

Increase fluid level, correct level control, install the pump lower down, vent the plant, clean the pipework, change the pipework, de-gas the medium, decrease the resistance in the supply pipe, fully open valves in the suction pipe, clean sieves and suction connections, install a venting valve directly before the non-return valve

x x x Wrong direction of rotation, incorrect electrical connection, too low rpm

Swap over two of the power supply phases in the terminal box, increase the rpm (*) (if necessary, get a new motor)

x x x Worn internal parts (e.g. the impeller) Remove foreign bodies out of the pump housing, replace worn parts

x x x Pump back-pressure is less than stated in the specifications, incorrect electrical connection

Set operating point precisely, increase counter-pressure by throttling the pump on the pressure side for example, turn off impeller if required (*), use larger motor (*), compare electrical supply with that on the motor rating plate; study the circuit diagram, see chapter 4.3.5

x x Higher density or higher viscosity of the delivery medium than specified

Re-adjust the pump (*)

x Cavitation Throttle the pump on the pressure side, correct the suction conditions, use larger pump (*)



(*) Please consult the manufacturer.

x Defective gaskets, pump badly adjusted, connecting screws loose

Replace gaskets, adjust the pump properly, check pipework connections, tighten connecting screws

x Shaft seal worn Replace shaft seal, check catchment liquid, check coolant supply lines, check bypass for clear cross-section

x Foreign body in the pump, motor bearings defective, circuit breaker tripped due to motor overload, circuit breaker too small, winding defective

Remove foreign body from pump housing, clean or replace pump housing, replace motor bearings, check electrical connection and compare with motor rating plate, if the motor is overloaded: Throttle the pump, smaller impeller (*), larger motor (*)

x x Impeller out-of-balance, bearing defective, too little or too much or the wrong lubricant

Clean the impeller, balance the impeller (*), replace bearings, add or reduce or completely replace the lubricant

x x x Pump wrongly adjusted, pump distorted or resonance vibrations in the pipework, several pumps on one console

Adjust pump precisely, check pipework connections / pump holder, individual installation, connect pipework via compensators, install vibration damper under the pump, make tank more rigid, clean pressure-relief holes in the impeller

x x x Delivery rate too low, pipework blocked, closed valve on the pressure side

Re-adjust the pump, for low volumes provide a bypass, clean the pressure pipe, switch pump on only when required, open valve on pressure side; use a smaller pump (*)

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17

6 Maintenance / RepairGeneral InstructionsThe operator must ensure that all maintenance,service and repair work on the pump is carriedout exclusively by authorised and speciallytrained persons. It must be established beyonddoubt that the person has studied the operator’smanual in detail.We recommend the creation and adherence toof a maintenance schedule. That will enable youto avoid expensive repairs and have a reliableand trouble-free pump operation.Only original spare parts must be used forrepairs. This is particularly important for themechanical seal (GLRD ).If work has to be carried out on themotor theinstructions in the manual from the relevantmotor manufacturer must be observed.

6.1 Maintenance / ServiceUse the following information to create amaintenance schedule. These arerecommendations of minimum requirementsthat must be adjusted to local conditions of useof the pump and may need amendingaccordingly.

6.1.1 ChecksContinuous checks:• Centrifugal pump delivery data (pressure,

amount)• Power take-up

Daily checks:• Pump running is quiet and vibration free• Bearing temperature• Leakage at the mechanical seal (GLRD )• SKS (catchment chamber system) – check

fluid level

Check / replace every 3 months:• Screws are tight• In case of SKS change the catchment

medium (if not otherwise instructed)

6.1.2 Lubrication and changinglubricant

Pumps of the types "ZH- / TH- / DUO" in thestandard models only run on bearings in thedrive motors. The bearings in small motors are designed tolast the useful life of the motor and are filled witha grease that cannot be replenished. Defectivebearings must be replaced. In this case thereare no lubrication nipples on the bearingsupports.Bearings in larger motors must be regularly re-lubricated. For more details please see the“Operating instructions for pump drives” inchapter 6 Service and maintenanceThe model with IEC Norm motor and bearingpedestal the bearings in the pedestal areprovided with a grease that need not bereplenished. It is designed to last the useful lifeof the motor and cannot be re-greased.Defective bearings must be replaced.

6.2 RepairGeneralAlways carry out repair work on the removedcentrifugal pump in an appropriate workshop. Besure to observe the general instructions at thebeginning of the chapter!The following instructions will enable you todismantle the pump and to re-assemble itproperly with the requisite spare parts in place.

Warning! Mortal danger!In order to prevent electric shocks, work on the terminal box and the machine controller must never be carried out before the electrical connections have been isolated or disconnected.

Warning! Mortal danger!The pump must be safeguardedagainst unintentional switching on(be disconnected) if checking ormaintenance work is to beundertaken.

Note:Please also observe the drawing inthe chapter “Spare parts / drawing”at the end of this operator’smanual!



When a new mechanical seal is fitted specialinstructions must be observed.The work can be undertaken with the usualworkshop tools. No special tools are needed.After dismantling thoroughly clean all theindividual parts of the centrifugal pump.

Check the individual parts for wear and damage.Parts that are not perfect must be reworked orreplaced.

6.2.1 Dismantling PreparationsPrior to starting to dismantle it the pump must besafeguarded against accidental switching on (itmust be disconnected).

When used in a facility, inform the shift leader ormanager.

6.2.2 Dismantling /Removal of the pump

The pump must be allowed to reach roomtemperature.• Disconnect the power supply.• Close valves (on the suction and pressure

sides).• Empty the pump via the drainage screws

912, 913• If there is a catchment chamber / pressure

chamber empty it via the drainage screws912. Dispose of the catchment medium inthe proper manner.

• Disconnect motor.• Remove existing additional connections.• Release pressure and suction nozzles.• Release pump from its base plate.• Lift the pump off completely (out of the tank

etc.)

When emptying the centrifugal pump pleaseobserve the following instructions!

6.2.3 Dismantling / Dismantling the pump

Before you beginBegin the work only once you have checkedthat:• The required spare parts are available and

that they will fit this pump or your particularmodel thereof. Or that the suspecteddamaged parts can be obtained promptly.Make sure that the pump serial number isstated in your spare parts order.

• You have all the required tools andaccessories for the work.

Warning! Mortal danger!Fasten a warning on the switchingcabinet.

Important:For the following work, please besure to observe local regulationsand conditions.

Warning!1. If the pump was used to deliver

liquids that are hazardous tohealth, then great care must betaken in emptying the pumpthat neither persons nor theenvironment are placed at riskthrough the process.

2. If necessary, wear protectiveclothing and protective mask!

3. The rinsing liquid used and anyresidual fluid out of the pumpmust be caught and disposedof properly and without placingpersons or the environment inany danger.

4. Pumps that deliver liquids thatare hazardous to health mustbe decontaminated. In drainingthe delivery medium off caremust be taken that neitherpersons nor the environmentare placed in any danger.

5. Legal requirements must beadhered to!

Note:Use only original spare parts for therepairs!All the gaskets must be replacedwhen the pump is re-installed.



19

Observing these instructions is a prerequisite fortrouble-free operation of the pump and for theacceptance of potential claims under guarantee.

6.2.4 Dismantling the pump (from the suction side)

Place the pump on its blower cover and secureagainst tipping over.

1st step:Variant 1 = ZHT, ZHB, TH, DUOLoosen the nuts 920.01 on the connectingscrews 905 on the clamping ring 531 (ZH3208) /suction cover 106/162 (ZH3213). Carefullyremove the suction cover.Variant 2 = ZHSLoosen the nuts 920.01 on the connectingscrews 905 on the suction stand 106/187.Carefully remove the suction stand.

2nd step:Loosen the impeller nut 922 and screw it off themotor shaft 819.Pull the first impeller 233/233.02 off the motorshaft 819 (with removal device).Dismantle the stage casing together with thepressed-in distributor147 or 109+171. Remove the key 940 out of its seat.Further steps (impeller, distributor, stage casing,distance washer 525, keys) pull off as describedabove.The last distributor 171 (ZH 3208) – seen in thedirection of flow – is pressed into the housingand prevented from twisting in the housing itselfby a locking pin 561.

3rd step: Dismantling the mechanical seal(GLRD )The mechanical seals used in the centrifugalpumps are not free of wear. When dismantlingthe pump check the mechanical seals fordamage. Damaged mechanical seals must becompletely replaced. Please observe thefollowing instructions for this.

There are two types of GLRD built into thepumps. Please observe the pumpspecifications.

a) GLRD not relieved – up to max. 13 barAfter loosening the locking ring 932 of the GLRDpull the sliding ring packet 433 off the shaft 819.

GLRD not relieved

b) GLRD relieved – up to max. 25 barCarefully pull the relieving bush 487 with themechanical seal packet 433 and O-Ring 412 offthe shaft Welle 819.

GLRD relieved

4th step:Loosen lock nut 924, if existing.Carefully pull off the housing 107/102 (106.02-DUO 3213) together with the pressed-in GLRDcounter-ring, without damaging the shaft.Now the counter-ring can be removed from itsseat in the now loose housing 107/102.

5th step:If existing, pull off lubrication ring / gamma ring423 (ZH3208).Remove intermediate piece 132.

6.2.5 Bearing pedestalIf your pump is equipped with an IEC Normmotor as drive, then there is a bearing pedestalfor supporting the pump shaft and the couplingbetween the cover plate and the motor. The bearings are enclosed and provided withgrease that cannot be replenished.

Customer service:Schmalenberger provides a 24hour service for the delivery ofspare parts!



The coupling is designed to last for the servicelife of the motor under normal operatingconditions.To replace the coupling or one of the bearings,proceed as follows:• Loosen the drive from the bearing pedestal.

Remove the motor with the upper half of thecoupling. Now you can replace the inner coupling part.

• To replace the ball bearings the pump mustbe removed and dismantled as described inchapter 6.2.4 .

• Then remove the bearing pedestal togetherwith the shaft from the cover plate.

• Remove the locking rings from the shaft andout of the bearing pedestal. Take out the ballbearings.

6.2.6 Intermediate piece / elongatedimmersion depth of the pump

Loosen the screws 914 holding the drive motorfrom the intermediate piece 132.Dismantle the drive 802, if necessary loosen thecover plate 167 from the intermediate piece 132.Replace the clamp gasket 400 8if existing).

6.2.7 Pump re-installationIn principle the re-installation is in the reverseorder of dismantling.Please observe by way of preparation:• Thoroughly clean all the individual parts of

all dirt.• Check all parts for wear. Damaged parts

must be replaced by new ones.• Clamp gaskets and O-rings must always be

replaced by new ones. Grease O-rings priorto installation.

Exception: Do not grease O-rings on the GLRD.See the special instructions for installing theGLRD.• When fitting the screw connections always

tighten alternately cross-wise. Use a torque wrench for this.

The following table shows the recommendedtorque to be applied for standard DIN 13 thread.

The figures apply to new, ungreased screws.Use of the screw strain limit of 90%.

6.2.8 GLRD installationPreparation:Increased cleanliness must be observed in theimmediate area where the GLRD installation isto take place.

Accessories:- Propyl alcohol and cellulose cloth (no cleaning

rags!)- O-ring lifter- Water and detergent

Work steps:• Unpack the GLRD and check for any

damage.

• Thoroughly clean all sliding surfaces withpropyl alcohol and cellulose cloths.

• In the case of GLRD with Elastomer bellows,to avoid friction when fitting the gasket,bellows and shaft should be moistened withwater whose surface tension has beenreduced by the addition of detergent, forexample.

• Cover the sliding surface with cardboarddisc.

• Press the counter-ring slowly and steadilyinto the holding seat.

Screw category: 5.6 6.9 8.8Screw M8 10.8 21.6 25.5 NMScrew M10 21.6 42.0 50.0 NMScrew M12 38.2 73.5 87.2 NMScrew M16 93.2 178 211 NM

Warning! Risk of damage!Never place sliding rings or theircounterparts onto the slidingsurface without using a protectivecover.

Warning!Under no circumstances must oil orgrease be used to assist with theassembly!



21

• Check that the counter-ring is seated atright-angles to the shaft axis.

• Clean the sliding surfaces to be striation freewith propyl alcohol and cellulose cloths.

Push the rotating unit (bellows unit, sliding ring)onto the shaft by turning gently clockwise untilthe sliding ring lies against the counter-ring.Then push the set collar further up to the markand fasten it to maintain the required initialstress. Ensure that the force is only applied viathe rear winding of the pressure spring.

Installation of the mechanical seal

In the back-to-back arrangement, as well as forthe GLRD without SKS, the required initial stressis produced through the installation of thelocking ring 932 and the washer 550.

You can order suitable guide bushes fromSchmalenberger GmbH & Co. KG.• Check that the thrust collar (spring collar),

spring and sliding ring sit tightly.Then continue with the assembly of the pump byfitting the keys, impellers, distributors and stagecasings.

6.3 Spare parts list / DrawingOn pages 107 - 120 there are the spare parts listand the drawing of your pump.Please take note of your pump type and therelevant model.

7 Appendix7.1 Shutdown / Storage /

ConservationEvery pump leaves the factory carefullyassembled. If initial operation is predicted to bea long time after delivery we recommend thefollowing measures for storage of the centrifugalpump.

7.1.1 Storage of New PumpsWhen requested, new pumps receive aconservation protection corresponding to thestorage time stated by the purchaser.

If this period of time is considerably exceededthe condition of the pump must be checked and,if required, re-conserved.

7.1.2 Longer Periods of Shutdown>3 months

1. Pump remains installedTo ensure that the pump is always ready foroperation and to prevent the formation ofdeposits inside the pump and in its immediatevicinity, the pump aggregate should be run for ashort time (approx. 10 minutes) monthly orquarterly during longer periods of inactivity.Prerequisite for this is that sufficient fluid issupplied to the pump.2. Pump is removed and storedTo remove the pump proceed as outlined inchapter 6 "Maintenance / Repair" .Prior to storing the pump it must be thoroughlycleaned and conserved. Conservation must bedone both internally and externally.

7.1.3 Restarting after Periods ofStorage

De-conservationBefore the stored pump is re-installed theconservation agent (covering or filling) must beremoved. Proceed as described in chapter 4.2.2"Cleaning" .

Important:Do not touch the sliding surfaceswith bare hands.

Important:Use a suitable guide bush to pushthe GLRD over the keyways, etc.without damaging it.



RestartingRe-install the pump according to the proceduredescribed in chapter 4.3 "Installing andconnecting".Immediately after completing the above work, allsafety and protective measures must beproperly installed and checked that theyfunction.Before the pump is re-started the checks andmaintenance measures stated in chapter 6.1"Maintenance / Service" must be carried out. Forthe new re-start the points listed in section 5.1"Initial start-up" must also be observed.Particularities of the mechanical seal:Prior to an initial start-up and after longerperiods of standstill or after a new mechanicalseal is installed it is important to check that thepump runs freely.The sliding ring and its counterpart ring can sticktogether very firmly due to adhesive forces. Theforce of the driving spring is then not enough tobreak the sliding ring away.In this case the shaft runs in the static seals andthe driving spring, which leads to damage.Remove the blower cover and turn the blowerwheel in the direction of the arrow. If there isresistance and the blower wheel feathers backthen the mechanical seal has to be removed andthe sliding ring and its counterpart ring must becarefully separated. Under no circumstances should the shaft beturned by force.

7.2 DisposalIf you want to take the pump completely out ofservice and never re-use it then please observethe local regulations for the disposal of industrialwaste.

7.3 Supporting documents forpump operation

The following documents are enclosed:- Operator’s manual- Dimensional sketchIn case of complaints regarding the pump motor,please contact us or the motor manufacturer.

7.4 Data sheetThe enclosed data sheet corresponds to thepump supplied.You are not allowed to change the dimensions ofthe pump.

Please also be sure to observe the otherdocumentation referred to in these operatinginstructions, see chapter 1.3 !

Warning!After long periods of storage underconservation conditions check theshape stability and elasticity of theElastomers (O-rings andmechanical seals). Brittle ringsmust be replaced. Elastomersmade of EPDM should be replacedin any event.

Warning! Mortal danger / poison!Pumps that have deliveredpoisonous, caustic or otherchemical substances which are adanger to people and theenvironment must be thoroughlycleaned and / or decontaminatedprior to being disposed of.The cleaning agents and rests ofthe delivery medium must also behandled in accordance with legalrequirements.If such legal regulations exist in thearea where the pump is operatedthen the pump must be completelydismantled and sorted into thedifferent materials so that they canbe disposed of separately.

Important:If changes have subsequentlybeen made to the pump suppliedthen any claims under theguarantee will be void.



23

7.5 Important Instructions7.5.1 Factory repairPlease observe the following instructions if thepump is sent back to the factory for repair:

1. If you send the pump back to themanufacturer for repair or an upgrade thenplease be sure to enclose precise details ofthe media that were delivered by the pump.

3. Only pumps that are completely empty andclean will be accepted for repair.

7.5.2 Ordering Spare PartsWhen ordering spare parts please do not fail togive us the following important information:• Pump serial number and type description or

alternatively the motor serial number• Delivery medium• Part number from the spare parts list• Part description• Material data from the specifications or the

order confirmation

The pump serial number is on the type platewhich is fastened to the blower cover of themotor.The order confirmation or motor serial numbermay also be of assistance.With this information you make it much easier forus to deliver the correct spare part for yourpump!

Warning!2. If the delivered media were

poisonous, caustic, etc. thenplease be sure to enclose acopy of the safety sheet for themedia!

Customer serviceSchmalenberger provides a 24 hourservice for the delivery of spareparts!

See our homepage under:www.schmalenberger.de

Head office address:Schmalenberger GmbH & Co. KGIm Schelmen 9 - 11D-72072 Tübingen

Telephone:+ 49 (0) 7071 - 7008-0

Telefax: + 49 (0) 7071 - 7008-59

Schmalenberger GmbH & Co. KGD-72013 Tübingen - Germany


8 Spare parts list and drawings

Note:The drawings of spare parts are illustrated in the following order:1. ZHT2. ZHS3. ZHB4. TH / THK5. DUO6. ZH with additional second pressure outlet7. ZHT with elongated immersion depth 8. Bearing pedestal for ZH

In the spare parts list (page 118 ff) all parts of all the pump types are listed.Not all parts are built into every pump, however.

25Pumpe Typ ZH- / TH- / DUOVersion: 27224 - B




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37


Pumpe Typ ZH- / TH- / DUO Version: 27224 - B

38



39

Schmalenberger GmbH + Co. KG Telefon: +49 (0)7071 70 08 - 0Strömungstechnologie Telefax: +49 (0)7071 70 08 - 59Im Schelmen 9 - 11 Internet: www.schmalenberger.deD-72072 Tübingen / Germany E-Mail: [email protected]

© 2009 Schmalenberger GmbH + Co. KG ; All rights reservedThis document is subject to change without notice

Circulating pumps Model ZHT / ZHB / ZHS / TH / THK / DUO-ZHB,-ZHS,-TH,-THK... · Circulating pumps...

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Transcript of Circulating pumps Model ZHT / ZHB / ZHS / TH / THK / DUO-ZHB,-ZHS,-TH,-THK... · Circulating pumps...