Rev.20112013

Installation Guide Sondex Industrial and Marine Pumps

2

1. CONTENT 2. Applications................................................................................................................................................................. Page 2 3. Operation...................................................................................................................................................................... Page 3 4. Maintenance................................................................................................................................................................ Page 4 5. Dis- and Reassembly................................................................................................................................................. Page 5 6. Wear ring Clearances................................................................................................................................................ Page 7 7. Part Description.......................................................................................................................................................... Page 7 8. Problem Analysis........................................................................................................................................................ Page 8 9. EC Declaration of Conformity - Industrial Pumps........................................................................................... Page 910. EC Declaration of Conformity - Marine Pumps................................................................................................ Page 10

2. APPLICATIONSReceiving pump

1. Inspect for shipping damage. If a shortage or damage occurs, contact the carrier immediately.

Location1. Install vertical with motor up. 2. Pump should be accessible for inspection and repair work, head room must be provided for the use of

hoist or tackle as necessary.3. Lift pump by slinging through motor eye bolts and securing the motor support.4. In no case should any part of motor be covered with insulation.

Foundation1. The pump must always be supported.2. Pumps with smaller motors may be suspended in the piping, provided the piping is supported

adjacent to the pump.3. For pumps with larger motors the pumps should be attached to a support utilizing the tapped holes

in the bottom of the pump casing. Note: Piping loads must not be applied to the pump.4. Pump must be allowed to move with piping movement. Expansion of the piping must be taken into

account when piping and suitable devices should be employed. Do not rigidly connect the pump to the floor. Note: provide vibrations isolations pads under floor mounted supports.

Do not support unit by motor eye bolts.

3

3. OPERATIONA. Before operating for the first time, check the following:

1. Is the motor correctly wired for voltage available?2. Has the pump been primed? Pump should never be run dry. Extra effort may be required to get the

air out of the seal chamber.

CAUTIONMake sure power supply to pump motor is locked out before touching motor shaft.

3. All rotating parts turn freely.

B. Starting pump1. Jog pump to check proper rotation.2. Start pump with discharge valve closed.

DANGERMAKE SURE SUCTION VALVE IS OPEN!!

3. When correct pressure has been reached, open discharge valve slowly.4. Do not operate pump for prolonged periods with discharge valve closed, so as to avoid

overheating and potential damaging loads.5. Pump should be stopped if any of the following occur: a. No discharge. b. Insufficient discharge. c. Insufficient pressure d. Loss of suction e. Excessive power consumption. f. Vibration

Check problem analysis further in the manual for help in troubleshooting.

4

4. MAINTENANCEA. Routine InspectionsRoutine inspections should be made on a regular basis. Inspections made while pump is running should reveal potential failures.

1. Inspect motor bearings for any sign of temperature rise. Temperature should not exceed 70°C. Temperature rise may indicate the early stages of bearing problems.

2. Listen for any unusual noise. a. Air trapped in pump. b. Hydraulic noise. c. Mechanical noise in motor and/or pump3. Check suction gauge reading and confirm that it is normal.4. Check discharge gauge reading and confirm that it is normal. a. If gauge readings are abnormal, find out why.

Note: Suction and discharge gauges should read the same with pump stopped.

B. Split Coupled PumpsThe pump shaft is attached to the motor shaft with a coupling. The pump shaft does not contain bearings that need lubrication.

C. Split Coupled MotorsSome motors must be lubricated in accordance with the manufacturer´s recommendations. Do not over lubricate the motor bearings as this could cause premature bearing failure.

D. Mechanical SealA mechanical seal is a very high-precision product and should be treated with extreme care before and during fitting. Replace the mechanical seal at minor and major pump rebuild or if leaking.

If you need to replace your mechanical seal, please contact your local Sondex supplier and state the serial number of the pump. At www.sondex.net you will find contact information to your local Sondex

5

5. DIS- AND REASSEMBLYA. GeneralIf the pump has been maintained and serviced properly, breakdowns which necessitate the pump being disassembled should not occur often.

1. If a problem occurs, the cause should be determined, if possible, before disassembling. (See “Problem Analysis”).

2. If the pump is being disassembled, all parts must be carefully handled, avoid heavy blows and shocks.3. All parts must be carefully cleaned and inspected for wear. Recondition or replace parts where

necessary.

B. Disassembly - Impeller Repair1. Drain liquid from casing by removing drain plug.

CAUTIONAllow pump to cool and close suction, and discharge valves before working on pump!!

2. Remove seal flush line.3. Remove bolts holding cover/motor adapter to casing. Pry cover/motor adapter and motor assembly

from casing or use jack bolts.4. Remove impeller bolt in a counterclockwise direction. Remove impeller and key.5. All parts must be cleaned and inspected for wear. Replace parts where necessary.

C. Disassembly - SealInternal seal removal and replacement:Remove the seal cover and shaft coupling.

Note: The shaft can drop if not properly supported in place, or the pump cover is on the pump casing.

The seal rotating element can be drawn off the shaft.

Note: Apply silicone grease on the outside of the shaft in the area between the seal and the end of the shaft.

This will help you remove the seal through the opening between the pump shaft and motor shaft. The stationary seal element is to be removed from the seal cover.

External seal removal and replacement:Loosen the two set screws on the seal rotating element. Remove the shaft coupling.

Note: The shaft can drop if not properly supported in place or the pump cover is on the pump casing.

Remove the seal rotating element.

Note: Apply silicone grease on the of the shaft in the area between the sealand the end of the shaft.

This will help you remove the seal through the opening between the pump shaft and the motor shaft. The stationary seal element is to be removed from the top of the cover/adapter after the snap ring is removed.

6

D. Reassembly - Impeller1. Assemble impeller key and impeller on shaft. Refit with impeller washer on

impeller bolt and tighten carefully. Be certain that the impeller rotates freely by hand.2. Apply a few spots of gasket adhesive to gasket surface and press against adhesive.3. Assemble cover-adapter complete with motor into casing. Ensure that gasket is seated correctly.

Install hex-headed cap screws into casing tapings and tighten uniformly.4. Reconnect seal flush line and drain plug.

E. Reassembly - Seal ReplacementInternal seal replacement:1. Be certain that all parts to be replaced are free from burrs, with screw threads and connecting faces

clear and free from damage.2. Insert stationary element of seal into seal cover.

Note: Do not touch the seal surfaces because this may result in leakage. Do not contaminate seal faces with fingerprints.

3. Lubricate the pump shaft end on the motor side with silicone grease. Do not use petroleum oil or grease.4. Place spring retainer and spring to abut against retaining ring. Slide rotary seal on shaft until it

contacts spring.5. Make sure the seal cover O-ring is properly seated in groove of seal cover. Place the seal cover back

onto the pump cover and bolt in place. Connect pump coupling to set shaft position.6. Reconnect seal flush line to drain plug.

External seal replacement: (Separate instructions are provided).1. Be certain that all parts to be replaced are free from burrs, with screw threads and connecting faces clear and free from damage.2. Insert stationary element of seal into seal cover.

Note: Do not touch the seal surfaces, because this may result in leakage. Do not contaminate seal faces with fingerprints.

Ensure the seal cover O-ring is properly seated in groove of the seal cover. Place the seal cover back onto the pump cover and bolt in place.

3. Install retaining ring in seal cover above stationary seal.4. Lubricate the pump shaft end on the motor side with silicone grease.

Do not use petroleum oil or grease.5. Slide rotary seal on shaft. Connect pump coupling to set shaft position.6. Slide rotating seal into final position and tighten the set screws, which will set proper seal position.7. Remove the plastic seal retaining clamps.8. Reconnect seal flush line to drain plug.

7

6. WEAR RING CLEARENCESInspectionOnce a year it is recommended to disassemble the pump. All rotating parts must be checked and repaired, if necessary.

Depending on the size and capacity of the pump, normal clearance between the impeller and casing wear ring is 0,45 to 0,50 mm.

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1,0

100 200 300 400 500

Max. clearance

Min. clearance

Wear ring diameter (mm)

Clearance (mm)

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1,0

100 200 300 400 500

The tolerance stated are average values, and must in each single case be compared with the needs for the necessary operation data.

Wear ring diameterThis applies to both upper and lower wear ring. Clearance

8

Item Part number Title Material Qty1 F0202011000XX Back plate Bronze / Cast iron 1

2 F0202011000XX Pump house Bronze / Cast iron 1

3 F0203011000XX Foot Cast iron 1

4 F0203011000XX Extension frame Cast iron 1

5 8100XX00XX44 Unbraco screw A4 1

6 F0234001100001 O-ring Nitril/NBR 1

7 F0202011000XX Impeller Bronze 1

8 F0202011000XX Wear ring (1+1 or 1+1.1) Bronze 2

9 8000XX00XX01 Hexagon screw Stainless steel 3

10 F0204020200XX Washer AISI 304 1

11 F0204020200XX Cover forextension frame Bronze, Soft Tin 2

12 820005001022 Slotted screw A2 6

13 820063001901 Hex head self drilling Steel, Mild 4

A-A ( 1 : 2 )

A

A

PARTS LISTQTYMATERIALTITLEPART NUMBERITEM

1BronzeBack plateF0202011000XX11BronzePump houseF0202011000XX21Cast IronFootF0203011000XX31Cast IronExtension frameF0203011000XX41A4Unbraco screw8100XX00XX4451Nitril/NBRO-ringF02340110000161BronzeImpellerF0202011000XX72BronzeWear ring (1+1 or 1+1.1)F0202011000XX83Stainless SteelHexagon screw8000XX00XX0191AISI 304WasherF0204020200XX102Bronze, Soft TinCover for extension frameF0204020200XX116A2Slotted screw M5 x 10 mm, DIN 963820005001022124Steel, MildHex head self drilling screw 6,3x19 DIN 7504K820063001901131 Mechanical seal Ø30, HuhnsealF0200000000XX143Steel, MildPLUG 1/4" 732014000004151Stainless SteelShaft for M90 to M280F0229021000XX161Stainless SteelFeather keyF0216021000XX173Galvanized SteelThreaded bar M10 x 20 DIN 91683001000200118

4/8Elgalv. qual. 8.8Washer, DIN 125 - A 138400XX000001194Stainless Steel, 440CHexagon screw, ISO 40178000XX00XX01202ElgalvanizedWasher, DIN 125 - A8400XX000001214ElgalvanizedUnbraco screw8100XX00XX01222Galvanized SteelUnbraco screw, ISO 47628100XX00XX01231Cast ironAdapter for M90 to M225F0203011000XX24

4/8Elgalv. qual. 8.8Washer, DIN 125 - A8400XX000001253Elgalv. qual. 8.8Washer, DIN 125 - A8400XX00000126

Assembly S-MP-80-80-174 Motor M160L, 50Hz/18,5kW, 60Hz/ 21,5kWImpeller ø174

F020000000016-AML

18-02-2013DOFR 00Date

DK-6000 KoldingJernet 9

ISO projektion

DateDesigned by Approved by

Drawing no.Rev. date

Rev. no.

Description:

SONDEX

Dimensions without tolerance:

Revision Text

Rev. by Sheet

ISO 2768-m

1 /2

955,

7

330

189

321,

260

4

140

2

3

12

18

16

24

13

11

4

20

19

1

6

9

7

14

5

8

15

26

10

17

21

23

22

25

8

7. PART DESCRIPTION

14 F0200000000XX Mechanical seal 1

15 732014000004 PLUG 1/4” Steel, Mild 3

16 F0229021000XX Shaft for M90 to M280 Stainless steel 1

17 F0216021000XX Feather key Stainless steel 1

18 830010002001 Threaded bar Galvanized Steel 3

19 8400XX000001 Washer Galvanized Steel 4/8

20 8000XX00XX01 Hexagon screw Stainless steel 4

21 8400XX000001 Washer Galvanized Steel 2

22 8100XX00XX01 Unbraco screw Galvanized Steel 4

23 8100XX00XX01 Unbraco screw Galvanized Steel 2

24 F0203011000XX Adapter for M90 to M225 Cast iron 1

25 8400XX000001 Washer Galvanized Steel 4/826 8400XX000001 Washer Galvanized Steel 3

9

8. PROBLEM ANALYSISA. No Discharge

1. Pump not primed.2. Speed too low.3. System head too high.4. Suction lift higher than pump is designed.5. Impeller completely clogged.6. Incorrect direction of rotation.7. Air leak in suction line.

B. Insufficient Discharge Flow1. Air leak in suction line.2. Speed too low.3. System head higher than anticipated4. Insufficient NPSH: Suction lift too high. Check gauges, also check for clogged suction

line or screen.5. Impeller partially plugged.6. Mechanical defects. a. Worn wear rings. b. Impeller damaged. c. Incorrect direction of rotation.

C. Insufficient Discharge Pressure1. Speed too low.2. System head less than anticipated.3. Air in system.4. Mechanical defects. a. Worn wear rings. b. Impeller damaged. c. Impeller diameter too small. d. Incorrect direction of rotation.

D. Loss of Suction1. Leak in suction line.2. Suction lift too high.3. Insufficient NPSH.4. Air in the system.5. Casing gasket defective.

E. Excessive Power Consumption1. Speed too high.2. System head lower than rating.3. Specific gravity of liquid too high.4. Mechanical defects. a. Shaft bent. b. Rotating elements bind. c. Worn wear ring.

F. Vibration1. Air leak in suction line.2. Air in system.3. Impeller partially plugged.4. Foundation not rigid.5. Mechanical defects. a. Damaged impeller. b. Motor bearings worn. c. Rotor out of balance. d. Shaft bent.

G. Motor Runs Hot1. Speed too high.2. Specific gravity of liquid too high.3. Mechanical defects. a. Shaft bent. b. Rotating elements bind. c. Defective motor. d. Voltage lower than rating

Sondex Pumps A/SJernet 9DK-6000 Kolding

Tel.: +45 8657 1344Fax. +45 8657 2488info@sondex-pumps.dkwww.sondex.dk

V.A.T. No.: DK-31576245

Bank: SydbankJernbanegade 14DK-6000 KoldingAcc.No.: 7040 0001415313Swift: SYBKDK22IBAN No.: DK2870400001415313

Overensstemmelseserklæring /EC declaration of conformity /Konformitätserklärung

Producent / Manufacturer / Hersteller

Sondex Pumps A/SJernet 9DK-6000 KoldingTel: +45 86 57 13 44

Repræsentant / Representative / Repräsentative

Erklærer på eget ansvar, at følgende produkter /Declare under our sole responsibility that the products /Erklärt eigenverantwortlich, daß die Produkte

Industripumper / Industrial pumps / IndustriepumpenSeries: S-IP

Som er omfattet af denne erklæring, er i overensstemmelse med følgende standarder /To which this declaration relates are in conformity with the following standards /Auf die sich diese Erklärung bezieht, den folgenden normativen Dokumenten entsprechen

Maskindirektivet / Machinery directive / Maschinenrichtlinie 2006/42/EU Appendix II AEMC-Direktivet / EMC-Directive / EMV-Richtlinie EMC 2004/108/EULavspændingsdirektivet / Low Voltage Directive / Niederspannungsrichtlinie LVD 2006/95/EU

10-04-2013

Aage Søndergaard NielsenManaging Director

Sondex Pumps A/SJernet 9DK-6000 Kolding

Tel.: +45 8657 1344Fax. +45 8657 2488info@sondex-pumps.dkwww.sondex.dk

V.A.T. No.: DK-31576245

Bank: SydbankJernbanegade 14DK-6000 KoldingAcc.No.: 7040 0001415313Swift: SYBKDK22IBAN No.: DK2870400001415313

Overensstemmelseserklæring /EC declaration of conformity /Konformitätserklärung

Producent / Manufacturer / Hersteller

Sondex Pumps A/SJernet 9DK-6000 KoldingTel: +45 86 57 13 44

Repræsentant / Representative / Repräsentative

Erklærer på eget ansvar, at følgende produkter /Declare under our sole responsibility that the products /Erklärt eigenverantwortlich, daß die Produkte

Marinepumper / Marine pumps / Marine PumpenSeries: S-MP

Som er omfattet af denne erklæring, er i overensstemmelse med følgende standarder /To which this declaration relates are in conformity with the following standards /Auf die sich diese Erklärung bezieht, den folgenden normativen Dokumenten entsprechen

Maskindirektivet / Machinery directive / Maschinenrichtlinie 2006/42/EU Appendix II AEMC-Direktivet / EMC-Directive / EMV-Richtlinie EMC 2004/108/EULavspændingsdirektivet / Low Voltage Directive / Niederspannungsrichtlinie LVD 2006/95/EU

10-04-2013

Aage Søndergaard NielsenManaging Director

10

Sondex Pumps A/SJernet 9DK-6000 Kolding

Tel.: +45 8657 1344Fax. +45 8657 2488info@sondex-pumps.dkwww.sondex.dk

V.A.T. No.: DK-31576245

Bank: SydbankJernbanegade 14DK-6000 KoldingAcc.No.: 7040 0001415313Swift: SYBKDK22IBAN No.: DK2870400001415313

Overensstemmelseserklæring /EC declaration of conformity /Konformitätserklärung

Producent / Manufacturer / Hersteller

Sondex Pumps A/SJernet 9DK-6000 KoldingTel: +45 86 57 13 44

Repræsentant / Representative / Repräsentative

Erklærer på eget ansvar, at følgende produkter /Declare under our sole responsibility that the products /Erklärt eigenverantwortlich, daß die Produkte

Industripumper / Industrial pumps / IndustriepumpenSeries: S-IP

Som er omfattet af denne erklæring, er i overensstemmelse med følgende standarder /To which this declaration relates are in conformity with the following standards /Auf die sich diese Erklärung bezieht, den folgenden normativen Dokumenten entsprechen

Maskindirektivet / Machinery directive / Maschinenrichtlinie 2006/42/EU Appendix II AEMC-Direktivet / EMC-Directive / EMV-Richtlinie EMC 2004/108/EULavspændingsdirektivet / Low Voltage Directive / Niederspannungsrichtlinie LVD 2006/95/EU

10-04-2013

Aage Søndergaard NielsenManaging Director

Sondex Pumps A/SJernet 9DK-6000 Kolding

Tel.: +45 8657 1344Fax. +45 8657 2488info@sondex-pumps.dkwww.sondex.dk

V.A.T. No.: DK-31576245

Bank: SydbankJernbanegade 14DK-6000 KoldingAcc.No.: 7040 0001415313Swift: SYBKDK22IBAN No.: DK2870400001415313

Overensstemmelseserklæring /EC declaration of conformity /Konformitätserklärung

Producent / Manufacturer / Hersteller

Sondex Pumps A/SJernet 9DK-6000 KoldingTel: +45 86 57 13 44

Repræsentant / Representative / Repräsentative

Erklærer på eget ansvar, at følgende produkter /Declare under our sole responsibility that the products /Erklärt eigenverantwortlich, daß die Produkte

Marinepumper / Marine pumps / Marine PumpenSeries: S-MP

Som er omfattet af denne erklæring, er i overensstemmelse med følgende standarder /To which this declaration relates are in conformity with the following standards /Auf die sich diese Erklärung bezieht, den folgenden normativen Dokumenten entsprechen

Maskindirektivet / Machinery directive / Maschinenrichtlinie 2006/42/EU Appendix II AEMC-Direktivet / EMC-Directive / EMV-Richtlinie EMC 2004/108/EULavspændingsdirektivet / Low Voltage Directive / Niederspannungsrichtlinie LVD 2006/95/EU

10-04-2013

Aage Søndergaard NielsenManaging Director

11

Sondex Head Office Jernet 9DK-6000 KoldingDenmarkTel. +45 76 306 100Fax (1) +45 75 538 968Fax (2) +45 75 505 019info@Sondex.dk www.Sondex.dk

Copyright © 2013 Sondex A/S Sondex A/S can accept no responsibility for possible errors in catalogues, brochures and other printet materials. Sondex A/S reserves the right at any time to change the specifications without notice.