Installation, Operation and Maintenance Instruction · 3.3 Bearings.....7 3.4 Approximate Value for...

Installation, Operation andMaintenance Instruction

Volute Casing Pumps

Model:

ICPICPI

ICPHICPIH

ICP 100-english Revision 00Article Nr. 4264412 Issue 05/2003

Keep for further use!Pay attention to this operatinginstruction before the delivery,

installation, start-up aso!

© ITT VOGEL-Pumpen

EC-Manufacturers Declaration (only valid for pump)acc. to Machine Directive 98/37/EG Appendix II B of European Parliament and Council of 22nd June 1998.

Manufacturer: Pumpenfabrik ERNST VOGEL GmbHA-2000 Stockerau, Ernst Vogel-Straße 2

Products: Pumps of model ICP, ICPI, ICPH, ICPIH

The mentioned products are intended for Installation into a machine1) / Assembly with other machines1). Their puttinginto operation is forbidden so long, till it is proven, that the machine, in which the pump shall be integrated,corresponds with the regulations of the Machine Directive 98/37/EG.

Used harmonised norms, especiallyEN 809EN 292 part 1EN 292 part 2

Used national technical norms and specifications, especiallyDIN 31001

The Declaration of the Manufacturer expires, when the pump is installed into units, where no declaration ofconformity, acc. to the Machine Directive 98/37/EG, is existing.

Stockerau, 22.05.2003 ................................................................................................

Robert SalzbauerQuality control

1) Strike out what´s not the case

EC-Declaration of Conformity on customer buyoutsIf essential components of the unit (e.g. motors) are provided by the customer and only the assembly ofthese components is made by Vogel, the whole conformity must be proved by the customer!

EC- Declaration of Conformity (only valid for units completely delivered by Vogel)acc. to Machine Directive 98/37/EG Appendix II A of European Parliament and Council of 22nd June 1998.


Products: Pump of model ICP, ICPI, ICPH, ICPIH

The mentioned products correspond with the regulations of the EC-Machine Directive 98/37/EG.

Used harmonised norms, especiallyEN 809EN 292 part 1EN 292 part 2EN 60204 part 1

Used national technical norms and specifications, especiallyDIN 31001

For Declaration of Conformity of appliances and / or components (e.g. motors) used with the unit, refer toattachments. The Declaration of Conformity expires, when the pump is installed into units, where no Declaration ofConformity, acc. to Machine Directive 98/37/EG, is existing.

Stockerau, 22.05.2003 ................................................................................................


EC-Declaration of Conformityacc. to Directive 94/9/EG (Atex) of European Parliament and Council of 23rd March 1994.


Products: Pumps of model ICP, ICPI, ICPH, ICPIH

are seen as appliances acc to Article 4 Paragraph 1.

The mentioned products are suitable for designated use as appliances of Appliance Group II, Appliance Catagory 2,explosive atmosphere by gases, vapors or mist, Ignition Protection Class "c", temperature class theoretically availableT1-T., whereby the temperature class T. is specified on the ATEX-plate and the maximum working temperature of thepumped liquid is shown on the type plate.

The Conformity acc. to Guideline 94/9/EG is only given on designated use - operating data corresponding to theinformation on data sheet and / or order confirmation.

Norms which must completely or partly be used regarding the Directive 94/9/EG "Appliances and ProtectionSystems for designated use in areas endangered to explosion":

EN 1127-1, Explosive Atmospheres - Explosion protection- Teil 1: Basis and Methodics.EN 13463-1, Non-electric appliances for application in areas endangered to explosion- Teil 1: Basis and Requirements.prEN 13463-5, Non-electric appliances for application in areas endangered to explosion- Teil 1: Constructive Safety (c).

For Declaration of Conformity of appliances and / or components (e.g. motors) used with the unit, refer toattachments. The Declaration of Conformity expires , when the pump is installed into units, where no Declaration ofConformity, acc. to Directive 94/9/EG and 98/37/EG (Machine Directive), is existing.The technical documents acc. Appendix VIII of Directive 94/9/EG were handed over to the TÜV Österreich -Prüfzentrum Wien, Deutschstraße 10, 1230 Wien. Identification-No. TÜV-A-WS/TPH-1/03/0402

Stockerau, 06.08.2003 ................................................................................................


Installation, Operating and Maintenance Instruction Model ICP

ICP 100-english page 1 Revision 00Article No 4264412 Issue 05/2003

TABLE of CONTENTS

Pump Name Plate ..................................................... 2

ATEX-Label (only for pumps in compliance withEC directive 94/9/EG)................................................ 2

1. General................................................................... 31.1 Guarantee ......................................................... 3

2. Safety Regulations ............................................... 32.1 Marking of References in the OperatingInstructions.............................................................. 32.2 Dangers of non-observance of the SafetyInstructions.............................................................. 42.3 Safety Instructions for the Operator / Worker ... 42.4 Safety Instructions for Maintenance, Inspectionsand Mounting Work................................................. 42.5 Unauthorized Alteration and Spare PartsProduction ............................................................... 42.6 Undue Operation............................................... 42.7 Explosion Protection.......................................... 42.8 Use acc. to Regulations .................................... 6

3. Description ............................................................ 63.1 Design ............................................................... 63.2 Shaft Sealing ..................................................... 63.3 Bearings ............................................................ 73.4 Approximate Value for Sound Pressure Level .. 73.5 Permitted Nozzle Loads and Torques at thePump Nozzles ... ..................................................... 7

4. Transport, Handling, Storage .............................. 84.1 Transport, Handling........................................... 84.2 Storage / Conservation...................................... 9

5. Mounting / Installation ......................................... 95.1 Mounting of Pump / Unit.................................... 95.2 Connection of Pipings to the Pump................... 9

5.3 Coupling...........................................................105.4 Drive ................................................................115.5 Electric Connection..........................................125.6 Final Control ....................................................12

6. Start-up, Operation, Shut down.........................126.1 Initial start-up ...................................................126.2 Switch on drive ................................................126.3 Restarting ........................................................126.4 Limits of Operation ..........................................136.5 Lubrication of Bearings....................................136.6 Monitoring ........................................................146.7 Shutting down ..................................................146.8 Storage / longer periods of non-operation .......14

7. Servicing, Maintenance ......................................147.1 General remarks..............................................147.2 Mechanical seals .............................................147.3 Stuffing boxes..................................................157.4 Lubrication and Change of Lubricant...............157.5 Coupling...........................................................157.6 Cleaning of pump ............................................15

8. Dismantling and repair of pump........................168.1 General remarks..............................................168.2 General ............................................................168.3 Disassembly of Back Pull Out Assembly.........168.4 Removal of Impeller.........................................168.5 Removal of Shaft Sealing ................................178.6 Removal of Bearing .........................................178.7 Reconditioning .................................................178.8 Mounting ..........................................................18

9. Recommended Spare Parts, Spare Pumps ......199.1 Spare Parts......................................................199.2 Stand-by pumps...............................................19

10. Faults - Causes and Solutions.........................19



Pump Name Plate

Type *) Type of pumpS/N *) Serial numberYear Year of constructionQ Rated capacity at the operating pointP Rated power at the operating pointH Head (Energy head) at the operating pointn Speedpall w C Max. permitted casing-operation-pressure

(=highest discharge pressure at the rated op-erating temperature to which the pump casingcan be used).

tmax op Maximum permitted operating temperature ofpumped liquid

Item NoCustomer related order numberImp∅ Outer diameter of the impeller

*) All details of design and materials are defined withthis information. They must be stated on all inquiries tothe manufacturer resp. orders of spare.

ATEX-Label (only for pumps in compliance with EC directive 94/9/EG)

CE Marking of compliance with the EC directive94/9/EG

Ex specific marking for explosion protectionII Symbol for the appliance group2G Symbol for the category (2), explosive atmos-

phere due to gases, vapors or mist (G)c Symbol for used ignition protection (construc-

tual safety "c")T1-T. Symbol for classification of the theoretically

available range of the temperature classes -data for temperature class refer to chapter2.7.5; Data for maximum permitted tempera-ture of pumped liquid refer to pump nameplate, data sheet and / or order confirmation.

The conformity with the EC directive 94/9/EG "Appli-ances and Protection Systems for designated use inareas endangered to explosion" is declared by theissue of the EC-Declaration of Conformity and theattachment of the ATEX-label at the pump (bearingbracket). The ATEX-label is attached additionally tothe pump name plate.



1. GeneralThis product corresponds with the requirements of theMachine directive 98/37/EG (former 89/392/EWG).

The staff employed on installation, operation,inspection and maintenance must be able toprove that they know about the relevant acci-dent prevention regulations and that they aresuitably qualified for this work. If the staff doesnot have the relevant knowledge, they shouldbe provided with suitable instruction.

The operation safety of the delivered pump resp. unit(= pump with motor) can only be guaranteed on des-ignated use according to the attached data sheet and /or order confirmation resp. chapter 6 "Start-up, Op-eration, Shut down".The operator is responsible for following the instruc-tions and complying with the safety requirementsgiven in these Operating Instructions.Smooth operation of the pump or pump unit can onlybe achieved if installation and maintenance are carriedout carefully in accordance with the rules generallyapplied in the field of engineering and electrical engi-neering.If not all the information can be found in these Oper-ating Instructions, please contact us.The manufacturer takes no responsibility for the pumpor pump unit if the Operating Instructions are not fol-lowed.These Operating Instructions should be kept in a safeplace for future use.If this pump or pump unit is handed on to any thirdparty, it is essential that these Operating Instructionsand the operating conditions and working limits givenin the Confirmation of Order are also passed on in full.

These Operating Instructions do not take into accountall design details and variants nor all the possiblechance occurrences and events which might happenduring installation, operation and maintenance.We retain all copyright in these Operating Instructions;they are intended only for personal use by the ownerof the pump or the pump unit. The Operating Instruc-tions contain technical instructions and drawings whichmay not, as a whole or in part, be reproduced, distrib-uted or used in any unauthorised way for competitivepurposes or passed on to others.

1.1 GuaranteeThe guarantee is given in accordance with our Condi-tions of Delivery and/or the confirmation of order.Repair work during the guarantee period may only becarried out by us, or subject to our written approval.Otherwise the guarantee ceases to apply.Longer-term guarantees basically only cover correcthandling and use of the specified material. The guar-antee shall not cover natural wear and tear and allparts subject to wear, such as impellers, shaft seal-ings, shafts, shaft sleeves, bearings, wear rings etc. ordamage caused by transport or improper handling.In order for the guarantee to apply, it is essential thatthe pump or pump unit is used in accordance with theoperating conditions given on the name plate, confir-mation of order and in the data sheet. This appliesparticularly for the endurance of the materials andsmooth running of the pump and shaft sealing.If one or more aspects of the actual operating condi-tions are different, we should be asked to confirm inwriting that the pump is suitable.

2. Safety RegulationsThese Operating Instructions contain important in-structions which must be followed when the pump isassembled and commissioned and during operatingand maintenance. For this reason, these OperatingInstructions must be read by the skilled staff responsi-ble and/or by the operator of the plant before it is in-stalled and commissioned, and they must be left per-manently available at the place where the pump orpump unit is in use.These Operating Instructions do not refer to theGeneral Regulations on Accident Prevention orlocal safety and/or operating regulations. The op-erator is responsible for complying with these (ifnecessary by calling in additional installationstaff).Equally, instructions and safety devices regardinghandling and disposal of the pumped media and/orauxilliary media for flushing, lubrication a.s.o., espe-cially if they are explosive, toxical, hot a.s.o., are notpart of this operating instruction.For the competent and prescribed handling only theoperator is responsible.

2.1 Marking of References in the Operat-ing InstructionsThe safety regulations contained in these OperatingInstructions are specially marked with safety signsacc. to nach DIN 4844:

Safety reference! Non-observance can impair the pump and itsfunction.

EC-Ex Marking Products intended for use in explosive atmos-pheres must be marked.

General Symbol for Danger! Persons can be endangered.

Warning of electric voltage!

Safety instructions attached directly to the pump resp.unit must be followed under any circumstances. Fur-ther they must be kept in good readable condition.In the same way, as these Operating Instructionsof the pump, all possibly attached Operating In-



structions of accessories (e.g. motor) must benoticed and kept available.

2.2 Dangers of non-observance of theSafety InstructionsNon-observance of the Safety Instructions canlead to loss of any claim for damages.Further, non-observance can lead to following risks:� Failure of important functions of the machine or

facility.� Failure of electronic appliances and measuring

instruments by magnetic fields.� Endangering of persons and their personal prop-

erty by magnetic fields.� Endangering of persons by electric, mechanic and

chemical influences.� Endangering of environment through leakage of

dangerous substances.

On application of the unit in areas endangeredto explosion special attention must be paid tosections marked with Ex.

2.3 Safety Instructions for the Operator /Worker� Depending on the operating conditions, wear and

tear, corrosion or age will limit the working life ofthe pump/pump unit, and its specified characteris-tics. The operator must ensure that regular in-spection and maintenance are carried out so thatall parts are replaced in good time, which wouldotherwise endanger the safe operation of thesystem. If abnormal operation or any damage areobserved, the pump must cease operation imme-diately.

� If the breakdown or failure of any system or unitcould lead to people being hurt or property beingdamaged, such system or unit must be providedwith alarm devices and/or spare modules, andthey should be tested regularly to ensure that theyfunction properly.

� If there is any risk of injury from hot or cold ma-chine parts, these parts must be protected againstcontact by the user, or suitable warning signsmust be affixed.

� Contact protection on moving parts (e.g. couplingguards) must not be removed from systems thatare in operation.

� If the sound level of a pump or pump unit is above85 dB(A) an ear protection has to be used whenstaying near the pump for some time.

� If dangerous media (e.g. explosive, toxic, hot) leakout (e.g. from shaft seals), these must be directedaway so that there is no danger to people or theenvironment. The provisions of the law must beobserved.

� Measures should be taken to exclude any dangerfrom electricity (e.g. by complying with the localregulations on electrical equipment). If work is car-ried out on live electrical components, they shouldbe unplugged from the mains or the main switch

turned off and fuse unscrewed. A motor protectionswitch is to be provided.

2.4 Safety Instructions for Maintenance,Inspections and Mounting Work� The operator is responsible that any maintenance,

inspections and mounting work is made byauthorized competent personnel, which must beinformed by havingng read the Operating Instruc-tions.

� Basically, all work on the pump or pump unitshould only be carried out when the pump is sta-tionary and not under pressure. All parts must beallowed to return to ambient temperature. Makesure that no-one can start the motor during suchwork. It is essential that the procedure for stoppingthe system described in the Operating Instructionsis observed. Pumps or pump systems that carrymedia that are dangerous to health must be de-contaminated before being taken apart. SafetyData Sheets for the various liquids handled. Im-mediately after finishing work, all safety and pro-tective devices must be replaced or restarted.

2.5 Unauthorized Alteration and SpareParts ProductionAlteration or changes of the machine are permittedafter agreement with the manufacturer.Original spare parts and accessory authorized by themanufacturer are serving the safety.The use of other parts can lead to loss of liability fortherefrom resulting consequences.

2.6 Undue OperationThe operating safety of the delivered machine canonly be guaranteed by designated use acc. to the fol-lowing chapters of the Operating Instructions. Thelimits stated in the data sheet and / or order confirma-tion must not be exceeded under any circumstances. 2.7 Explosion ProtectionOn application of units in areas endangered to explo-sion measures and references in the chapters 2.7.1 to2.7.6 must be observed, so that explosion protection isguaranteed. 2.7.1 Filling of unit

During operation of the pump the system of thesuction and pressure pipe and the pump itselfmust permanently be filled with the pumpedliquid. Thus, no explosive atmosphere can de-velop and the danger of dry-run is avoided.

If the operator can´t guarantee that, accordingmonitoring measures must be provided.

Equally all seal casings, auxiliary systems of theshaft sealing, as well as heating and coolingsystems must be filled carefully.



2.7.2 Marking

The marking of the pump refers to the pumpitself. For coupling and motor resp. further addi-tions a separate Declaration of Conformity, aswell as a corresponding marking must be avail-able.

Example of of marking at pump:CE Ex II 2 G c T... . The marking shows the theoretically applicable rangeof temperature classes. The different temperatures,permitted acc. to pump design, result as shown inchapter 2.7.5. The same is valid for the drive. For a whole unit (pump, coupling, motor) with differenttemperature classes the lowest is valid. 2.7.3 Rotation Control

Carry out rotation control with speparated cou-pling halves only! Refer to chapter 5.5 and 6.1as well.

If danger of explosion is also existing duringinstallation, the rotation control must not becarried out by short start-up of the empty pump,to avoid undue temperature increase in case ofcontact of rotating and stationary parts.

2.7.4 Operation of pump The pump must only be started up with fully openedsuction side and slightly opened pressure side valve.The start-up against closed non-return valve, however,is possible. Immediately after the start-up the dis-charge side valve must be adjusted to the operatingpoint. Refer to chapter 6.2, as well. Operation with closed valve in suction and / ordischarge pipe is not permitted!

There´s a danger, that high surface tempera-tures are developing at the pump casing afterrelatively short time, through fast heating of theliquid inside the pump.

Fast pressure increase inside the pump canlead to overload and, thus, the pump can burst.

In chapter 6.4.1 the minimum flow is stated. Longeroperating phases with these flows and the namedliquids don´t cause additional increase of surface tem-perature at the pump. Furthermore the references in chapter 6 of these op-erating Instructions must be taken into consideration.

On pumps with mech. seals the permitted tem-perature limits can be exceeded due to dry-run.Dry run not only can occur on insufficientlyfilled seal casing, but also because of too muchgas in the medium. Operation of the pump out of the permittedoperating range can lead to dry-run, as well.

2.7.5 Temperature Limits

Under normal operating conditions the highesttemperatures must be expected at the surfaceof the pump casing and in the area of the bear-ings.

The surface temperature occurring at pump casingcorresponds with the temperature of the pumped liq-uid.

If the pump is heated (e. g. heating jacket), caremust be taken, that the temperature classes,prescribed for the plant are observed.

In the area of the bearing bracket free contact fromsurface to surrounding must be given.

During operation of the pump it must be se-cured that an overabundant sedimentation ofdust is avoided (regular cleaning), to preventheating of pump surface over the permittedtemperature.

The operator of the plant must secure that thedefined operating temperature is observed. Themax. allowed temperature of the pumped liquid atsuction depends on the particular temperatureclass. The following table shows the theoretical temperaturelimits of the pumped liquid in consideration of the tem-perature classes acc. to EN 13463-1.

Temperature class acc.EN 13463-1

Temperature limit ofpumped liquid

T4 (135°C) 135°C T3 (200°C) 180°C T2 (300°C) 260°C T1 (450°C) 260°C

The particular allowed operating temperature ofthe pump is shown in the data sheet and / orthe order confirmation resp. the type plate at thepump.

In the area of the bearings the temperature class T4 isguaranteed, provided that the ambient temperature is40°C and the appliance is duly operated and main-tained. 2.7.6 Maintenance

For a secure and reliable operation it must besecured by regular inspections, that the unit ismaintained competently and is kept in goodtechnical condition.

Example: Function of bearings. Operation and appli-cation conditions are essentially responsible for theirachievable life cycle. By regular control of the lubricant and the runningsound the danger of occurring over temperatures bybearings running hot or defect bearing seals isavoided. Refer to chapter 6.6 and 7.4. The function of the shaft sealing must be secured byregular control.



If auxiliary systems (e.g. external flushing, cooling,heating) are installiert, it must be checked, if monitor-ing devices are necessary to secure the function. 2.7.7 Electric switches and control device, Instru-mentation and accessories

Electric switches and control devices, instru-mentation and accessories like e.g. flush tanks,a.s.o., must correspond with the valid safetyrequirements and regulations for explosionprotection.

2.8 Use acc. to Regulations2.8.1 Speed, Pressure, Temperature

Suitable safety measures must be taken at theplant to ensure that the speed, pressure andtemperature of the pump and the shaft sealingdo not exceed the limit values given in the datasheet and / or order confirmation. The givenadmission pressures (system pressures) mustalso be sufficiently high.

Further, pressure shocks, as can occur on too fastshut down of the facility, must be kept away from thepump (e.g. by non-return valve at pressure side, flywheel, airtanks). Quick temperature changes must beavoided. They could cause a temperature shock andlead to damage or impair the function of single com-ponents. 2.8.2 Permitted Nozzle Loads and Torques

Basically the suction and discharge piping mustbe designed in such way, that as little forces aspossible are effective to the pump. If that is notpossible, the values shown in chapter 3.5 mustnot be exceeded under any circumstances. Thisis valid for the operation as well as for thestandstill of the pump and therefore for all pos-sible pressures and temperatures of the unit.

2.8.3 NPSH

The pumped liquid must have a min. pressureNPSH at the impeller inlet, so that cavitationfree work is secured resp. a "break off" of thepump flow is prevented. This condition is ful-filled, when NPSH-value of the system(NPSHA) lies above NPSH-value of the pump(NPSHR) under all operating conditions.

Attentention must especially be piad to the NPSH-value on pumping liquids near the vapour pressure. Ifthe NPSH-value of the pump remains under, this canlead from damage of the material due to cavitation todestruction by overheating. The NPSH-value of the pump (NPSHR) is shown inthe curves of every pump type. 2.8.4 Sealing, Flushing, Cooling Suitable provisions for the regulation and monitoring ofsealing, flushing or cooling are to be provided. When handling dangerous liquids or if temperaturesare high, care should be taken to ensure that thepump ceases operating if the sealing, flushing orcooling system fails. Sealing, flushing and cooling systems must always beoperational before the pump is started up. Theyshould not be taken out of operation until the pumphas stopped, provided that the nature of the operationallows this at all. 2.8.5 Back Flow In systems where pumps are operating in closed cir-cuits under pressure (gas cushions, steam pressure),the pressure of the gas cushion must not be reducedvia the pump, since the back flow speed may be muchhigher than the operating speed, which would destroythe unit.

3. Description3.1 Design ICP-pumps are single-stage volute casing pumps inprocess design. Hydraulic design and dimensionscomply with ISO 2858/ EN 22858, the technical designcomplies with ISO 5199/EN 25199. For pump pres-sure up to 25 bar and volute casing with centerlinefeet. ICPI-pumps as design ICP, except that they have aninducer. ICPH- and ICPIH-pumps pumps additionally possessa cooling or heating of the casing cover and/or thevolute casing. The pumps are designed as modular systems andcan, therefore, be delivered in many variants (e.g.different materials, shaft sealings, different kinds oflubrication, cooling / heating, a.s.o.).

The permitted application conditions and design de-tails of the delivered pump are shown in the attacheddata sheet and / or order confirmation. 3.2 Shaft Sealing Basically there are two kinds of shaft sealing: thepaccking and the mechanical seal, whereas, thereagain are many variants of both kinds. At the datasheet and / or the order confirmation the shaft sealingtype of your pump is shown. An instruction for the packing of a stuffing box resp.for the mounting and operation of mech. seals can befound in the appendix of the particular "Mounting In-structions of the Shaft Sealing".

In areas endangered to explosion the use ofpumps with packings is forbidden!



Further details about packings and mech. seals,as well as the therewith connected accidentaldangers, you can find in chapter 6.6 and inchapters 7.2 and 7.3.

3.3 Bearings The pump shaft is guided by antifriction bearings. Inthe data sheet and / or order confirmation you cansee, if your pump is designed for oil lubrication (stan-dard design) or grease lubrication (special design).

In areas endangered to explosion the use ofpumps with grease lubricated bearings is for-bidden!

3.3.1 Used bearings The size of the bearing bracket of your pump is shownin the data sheet and / or order confirmation.

Bearing type Bearing bracket pump side drive side 24 6307 - C3 3307A - C3 32 6309 - C3 3309A - C3 42 6311 - C3 3311A - C3 48 6313 - C3 3313A - C3

3.3.2 Oil Sump Cooling On temperatures of the pumped liquid over 160°C anoil sump cooling is required. For connection refer to list "Connections" in the annex.� For cooling use pure, non-aggressive water with a

maximum incomming temperature of 30°C.� Cooling water should be hand-warm at discharge.� The pressure in the cooling system must not ex-

ceed max. 6 bar.� Provide control devices for temperature and pres-

sure monitoring.

3.4 Approximate Value for Sound Pres-sure Level

Sound pressure level LpA in dB(A)Pump alone Pump + Motor

Nominalpower PNin kW

2950min-1

1450min-1

975min-1

2950min-1

1450min-1

975min-1

0,55 50,5 49,5 49,0 58,0 52,0 51,50,75 52,0 51,0 50,5 59,0 54,0 53,01,1 54,0 53,0 52,5 60,0 55,5 54,51,5 55,5 55,0 54,5 63,5 57,0 56,02,2 58,0 57,0 56,5 64,5 59,0 58,53,0 59,5 58,5 58,0 68,5 61,0 62,04,0 61,0 60,0 59,5 69,0 63,0 63,05,5 63,0 62,0 61,5 70,0 65,0 65,07,5 64,5 63,5 63,0 70,5 67,0 67,0

11,0 66,5 65,5 65,0 72,0 69,0 68,515,0 68,0 67,0 66,5 72,5 70,0 70,518,5 69,0 68,5 68,0 73,0 70,5 74,022,0 70,5 69,5 69,0 74,5 71,0 74,030,0 72,0 71,0 70,5 75,0 72,0 73,037,0 73,0 72,0 71,5 76,0 73,5 73,545,0 74,0 73,0 72,5 77,0 74,5 73,555,0 75,5 74,5 74,0 78,0 75,5 75,075,0 77,0 76,0 75,5 80,0 76,5 76,090,0 78,0 77,0 -- 80,5 77,5 --110,0 79,0 78,0 -- 82,5 78,5 --132,0 80,0 79,0 -- 83,0 79,5 --160,0 81,0 80,0 -- 83,5 80,5 --

Sound pressure level LpA measured in 1 m distancefrom pump surface acc. to DIN 45635, part 1 and 24.Room and foundation influences are not considered.The tolerance for these values is ±3 dB(A).Addition with 60 Hz-operation:Pump alone: −Pump with motor: +4 dB(A)

3.5 Permitted Nozzle Loads and Torquesat the Pump Nozzles ...... following the Europump-Recommendation forpump acc. to ISO 5199.The data for forces and torques are only valid for staticpiping loads.The values given in the chart are valid for pump unitswith standard-ICP-base frames (ungrouted).All values for forces and torques refer to standardmaterials EN-GJS400-18LT and 1.4408.

pic 1



Suction nozzle Discharge nozzleForces in N Torques in Nm Forces in N Torques in NmSizes ∅DN Fx Fy Fz �F Mx My Mz �M ∅DN Fx Fy Fz �F Mx My Mz �M

40-25-160 40 1250 1100 1000 1950 1300 900 1050 1900 25 750 700 850 1300 900 600 700 130040-25-200 40 1250 1100 1000 1950 1300 900 1050 1900 25 750 700 850 1300 900 600 700 130040-25-250 40 1250 1100 1000 1950 1300 900 1050 1900 25 750 700 850 1300 900 600 700 130050-32-160 50 1650 1500 1350 2600 1400 1000 1150 2050 32 900 850 1050 1650 1100 750 850 160050-32-200 50 1650 1500 1350 2600 1400 1000 1150 2050 32 900 850 1050 1650 1100 750 850 160050-32-250 50 1650 1500 1350 2600 1400 1000 1150 2050 32 900 850 1050 1650 1100 750 850 160050-32-315 50 1650 1500 1350 2600 1400 1000 1150 2050 32 900 850 1050 1650 1100 750 850 160065-40-160 65 2100 1850 1700 3300 1500 1100 1200 2200 40 1100 1000 1250 1950 1300 900 1050 190065-40-200 65 2100 1850 1700 3300 1500 1100 1200 2200 40 1100 1000 1250 1950 1300 900 1050 190065-40-250 65 2100 1850 1700 3300 1500 1100 1200 2200 40 1100 1000 1250 1950 1300 900 1050 190065-40-315 65 2100 1850 1700 3300 1500 1100 1200 2200 40 1100 1000 1250 1950 1300 900 1050 190080-50-160 80 2500 2250 2050 3950 1600 1150 1300 2350 50 1500 1350 1650 2600 1400 1000 1150 205080-50-200 80 2500 2250 2050 3950 1600 1150 1300 2350 50 1500 1350 1650 2600 1400 1000 1150 205080-50-250 80 2500 2250 2050 3950 1600 1150 1300 2350 50 1500 1350 1650 2600 1400 1000 1150 205080-50-315 80 2500 2250 2050 3950 1600 1150 1300 2350 50 1500 1350 1650 2600 1400 1000 1150 2050

100-65-160 100 3350 3000 2700 5250 1750 1250 1450 2600 65 1850 1700 2100 3300 1500 1100 1200 2200100-65-200 100 3350 3000 2700 5250 1750 1250 1450 2600 65 1850 1700 2100 3300 1500 1100 1200 2200100-65-250 100 3350 3000 2700 5250 1750 1250 1450 2600 65 1850 1700 2100 3300 1500 1100 1200 2200100-65-315 100 3350 3000 2700 5250 1750 1250 1450 2600 65 1850 1700 2100 3300 1500 1100 1200 2200125-80-160 125 3950 3550 3200 6200 2100 1500 1900 3050 80 2250 2050 2500 3950 1600 1150 1300 2350125-80-200 125 3950 3550 3200 6200 2100 1500 1900 3050 80 2250 2050 2500 3950 1600 1150 1300 2350125-80-250 125 3950 3550 3200 6200 2100 1500 1900 3050 80 2250 2050 2500 3950 1600 1150 1300 2350125-80-315 125 3950 3550 3200 6200 2100 1500 1900 3050 80 2250 2050 2500 3950 1600 1150 1300 2350125-80-400 125 3950 3550 3200 6200 2100 1500 1900 3050 80 2250 2050 2500 3950 1600 1150 1300 2350125-100-200 125 3950 3550 3200 6200 2100 1500 1900 3050 100 3000 2700 3350 5250 1750 1250 1450 2600125-100-250 125 3950 3550 3200 6200 2100 1500 1900 3050 100 3000 2700 3350 5250 1750 1250 1450 2600125-100-315 125 3950 3550 3200 6200 2100 1500 1900 3050 100 3000 2700 3350 5250 1750 1250 1450 2600125-100-400 125 3950 3550 3200 6200 2100 1500 1900 3050 100 3000 2700 3350 5250 1750 1250 1450 2600150-125-250 150 5000 4500 4050 7850 2500 1750 2050 3650 125 3550 3200 3950 6200 2100 1500 1900 3050150-125-315 150 5000 4500 4050 7850 2500 1750 2050 3650 125 3550 3200 3950 6200 2100 1500 1900 3050150-125-400 150 5000 4500 4050 7850 2500 1750 2050 3650 125 3550 3200 3950 6200 2100 1500 1900 3050200-150-250 200 6700 6000 5400 10450 3250 2300 2650 4800 150 4500 4050 5000 7850 2500 1750 2050 3650200-150-315 200 6700 6000 5400 10450 3250 2300 2650 4800 150 4500 4050 5000 7850 2500 1750 2050 3650200-150-400 200 6700 6000 5400 10450 3250 2300 2650 4800 150 4500 4050 5000 7850 2500 1750 2050 3650

4. Transport, Handling, Storage4.1 Transport, Handling� Check the pump / pump unit immediately upon

delivery / receipt of despatch for damage or miss-ing parts.

� The pump / pump unit must be transported care-fully and by competent personnel. Avoid seriousimpacts.

� Keep the pump/pump unit in the same position inwhich it was supplied from the factory. Take noteof the instructions on the packaging.

� The suction and discharge side of the pump mustbe closed with plugs during transport and storage.

Dispose of all packing materials in accordancewith local regulations.

� Lifting devices (e.g. fork-lift truck, crane, crane

device, pulleys, sling ropes, etc.) must be suffi-ciently strong and must only be used by authorizedpersons. The weight of the pump / pump unit isgiven in the data sheet.

� The pump / pump unit may only be lifted by solidpoints such as the casing, flanges or frame. Pic-ture 2 shows the correct method of carrying bycrane.

pic 2

Do not stand underneath suspended loads.Take note of the general regulations on preven-tion of accidents. The pump / pump unit must be secured againsttipping over and slipping until it has been fixedin its final location.

Sling ropes must not be fixed to ends of shaftsor the ring loops of the motor.

Slipping out of the pump / pump unit of thetransport lifting device can cause damages topersons and things.



4.2 Storage / Conservation Pumps or units, which are stored over a longer periodbefore start-up (max. 6 months), must be protectedfrom moisture, vibrations and dirt (e.g. by wrapping inoil paper or plastic). Pumps must basically be stored ina place where they are protected from the weather,

e.g. under dry cover. During this time, all suction anddischarge branches and all other intakes and outletsmust be closed with dummy flanges or plugs. For longer periods of storage conservation measure-ments at machined surfaces and packing with mois-ture protection can be necessary!

5. Mounting / Installation5.1 Mounting of Pump / Unit The pump and motor (= pump unit) must be providedwith a base frame made of steel or cast iron or a fabri-cated (welded) frame, where this does not exist al-ready or if it is not included in the delivery. This baseframe must be placed on a foundation which can with-stand all loads that arise during operation (refer tochapter 5.1.2). When mounting the pump onto the base frame thefollowing must to be noticed:� The base frame must be solid, so that there won´t

occur any twists or vibrations during the operation.� The mounting surfaces of the pump feet and mo-

tor on the base frame must be flat (machining isrecommended). Bracing of the pump leads topremature breakdown of the pump and to a loss ofwarranty.

� The drillings for the pump mounting must be insuch a way, that safe fastening is guaranteed.

� Between pump and motor shaft an adequatespace must be left depending on the used cou-pling, refer to chapter 5.3.

5.1.1. Mounting the unit to a foundationThe place, where the pump is mounted must be pre-pared acc. to the dimensions of the dimensionaldrawings. The concrete foundations should have suffi-cient firmness acc. to DIN 1045 or equal standard(min. BN 15), to ensure a secure, functional mounting.The concrete foundation must have set, before theunit is errected. Ist surface must be horizontal andeven.

Sufficient space must be provided for mainte-nance and repair work, especially for replacingthe drive motor or the complete pump unit. Themotor fan must be able to take in enough coolair, and the intake grille must therefore be atleast 10 cm away from any wall, etc.

� For the set of anchor bolts according recesses

must be provided. If that is not the case, concreteexpansion bolts resp. epoxy capsle anchor boltscan be used.

� When mounting the pump on the foundation itmust be adjusted at the discharge nozzle bymeans of a spirit-level (at discharge nozzle). Thepermitted deviation is 0,2 mm/m. After insertingthe foundation bolts they must be cast in the foun-dation with concrete. After setting of the grout thecoupling alignment must be checked accordingchapter 5.3.1 and possible misalignments must becorrected by adjusting foundation frame in the

area of the drive motor. The smoothness of thebase frame must be 0,2 mm/m before it is filled upresp. fastened. For adjustment leveling shims orleveling screws (optional, not delivered standard-wise) can be used. Levelling shims must be in-serted next to the foundation anchors and must lieplainly. After that fasten foundation bolts symmet-rically but only slightly. Fill in base frame with nonshrinking grout.

Notice:� Avoid air bubbles (e.g. by vibrating).� Check that the grout has properly set and hard-

ened.� Take care for the after-treatment of the concrete

acc. to DIN 1045. After setting, tighten the foundation anchor evenly andfirmly. Check alignment of coupling acc. to chapter5.3.1 and re-adjust, if necessary. Further, check thatall screws between pump / motor and the base framefit snugly. Although the original ICP-base frames are designedsolidly, the filling in of the adjusted base frame up tothe rim is recommended. � If vibrations are transmitted to the foundation from

adjoining components, it must be guarded throughadequate vibration damping paddings (vibrationsfrom outside can impair the bearing).

� To prevent vibrations being transmitted to adjoin-ing components, the foundation should be laid ona suitable insulating base.

The size of these insulating pads will vary, de-pending on circumstances, and should there-fore be determined by an experienced special-ist.

5.2 Connection of Pipings to the Pump

The pump must not be used as fixed point forthe piping. The permitted piping loads must notbe exceeded, refer to chapter 3.5.

5.2.1 Suction and discharge pipe� The pipes must be of a size and design that liquid

can flow freely into the pump and that the pumpfunctions without problems. Particular attention isto be paid to ensuring that suction pipes are air-tight and that the NPSH values are observed. Un-der suction lift condition lay the suction pipe in thehorizontal section towards the pump so that it isslightly inclined upwards so that no air traps occur.



Under positive suction head condition install thesuction pipe work slightly declined towards thepump. Do not install fittings or elbows right beforethe suction nozzle.

� If the suction supply is under vacuum and en-trained gas may be present in the liquid, it is rec-ommended that a vent line be considered up-stream of the pump suction with return to the suc-tion supply, above the max liquid level.

� An additional flushed piping - discharge branch-vent line - makes it easier to de-aerate the pumpbefore start-up (pic 3).

pic 3 � When laying the pipes, make sure that the pump

is accessible for maintenance, installation anddisassembly.

� Notice "Permitted Forces on Flanges" (chapter3.5).

� If expansion joints are used in the pipes, theyhave to be supported in such a way that the pumpis not loaded unduely high because of the pres-sure in the pipes.

� Before connecting up to pump: remove protectivecoverings from suction and discharge branches.

� Before starting up, the pipe system, fittings andequipment must be cleaned to remove weld spat-ter, scale etc. Any pollutants are to be completelyremoved from pump units that are directly or indi-rectly connected to drinking water systems beforebeing installed and taken into use.

� To protect the shaft sealing (especially mechanicalseals) against foreign impurities, it is recom-mended that a sieve, 800 micron, is installed inthe suction/intake pipe when the motor is beingstarted up.

� If the pipe system is tested with the pump in-stalled, do not exceed the maximum permittedcasing pressure of the pump and/or shaft sealing(see data sheet).

� When emptying the pipe after the pressure test,make sure that the pump is treated properly (dan-ger of rust and problems when starting up).

� In the case of pumps with stuffing boxes, replacepacking after pressure test (packing may be over-compressed and thus no longer suitable for use).

5.2.2 Additional connections Any required sealing, flushing or cooling pipe connec-tions must be installed. Please consult the data sheetto see which pipes, pressures and amounts are nec-essary. The position and size of connections to thepump are given in the appendix, "Connections".

These connections are essential for the func-tion!

It is recommended that a pipeline is installed to takeoff any leakage from the shaft seal. For connection,see appendix, "Connections". 5.3 Coupling

Make sure that nobody can start the motor dur-ing work on the coupling. According to Accident Prevention Regulations,the pump unit may only be operated when thecoupling guard is mounted.

On operation in zone 1 and 2 a coupling withvalid Atex-certification must be used.

The Operating Instructions of the manufacturermust be followed. 5.3.1 Alignment of coupling

The alignment of the coupling must be carriedout with the utmost care and attention, so thatthe unit will operate without failure. If you do notpay attention to this hint you will lose your war-ranty!

After mounting onto the foundation and theconnection of the pipings the coupling must beadjusted again, even, if the unit was deliveredcompletely mounted on the frame.

� Before starting installation, carefully clean shaft

ends and coupling components.� Before adjusting the coupling unfasten screws

(901.12) between bearing bracket (330) and cas-ing foot (183) and only fasten again after the ad-justment. Repeat measurement after fastening ofscrews (901.12).

� The unit is properly aligned, when a ruler, which islaid axially over both coupling halves, has thesame distance to the particular shaft everywhereon the circumference. Further, both couplinghalves must have the same distance to one an-other on every of the circumference. This must bechecked by means of a tracer, gauge or dial gage;refer to pic. 4 and 5.

� The permitted tolerances for your coupling isshown in the operating instructions of the cou-pling. For the exact characterization of your cou-pling refer to data sheet and / or order confirma-tion.



pic 4 - Alignment of coupling with gauge and ruler

pic 5 - Alignment of coupling with spacer

Control alignment of coupling again in operationwarm condition and on system pressure (ifavailable) and correct, if necessary. Pay atten-tion to chapter 6 beforehand! It must be possi-ble to turn the unit easily and harmoniously byhand.

Improper alignment of the unit can lead to dam-ages at coupling and unit!

Mount coupling guard after alignment and be-fore start-up.

5.3.2 Coupling Guard

Acc. to accident prevention regulations thepump must only be operated with couplingguard.

Care has to be taken, that the used couplingguard consits of non-sparking material.

Parts:

Assembly:

5.4 Drive On selecting the motor size care has to be taken, thatthe requirements acc. to ISO 5199 are fulfilled. Notethe Operating Instructions of the motor manufac-turer.

On application in zone 1 and 2 a motor withvalid Atex-certification must be used.

ruler gauge

ruler gauge



5.5 Electric Connection

Electrical connection work may only be carriedout by an authorised professional. The rulesand regulations valid for electrical technology,especially those concerned with safety meas-ures, must be observed. The regulations of thenational power supply companies operating inthat area must also be observed.

Before starting work, check that the information on themotor name plate is the same as the local mains net-work. The power supply cable of the coupled drivemotor must be connected up in accordance with thewiring diagram produced by the motor manufacturer. Aprotective motor switch must be provided.

In areas endangered to explosion IEC 60079-14must additionally be noticed for the electric in-stallation.

Care must be taken that the base frame (2xM10-thread available for earthing screws) isearthed by means of corresponding measures.

The direction of rotation must only be checkedwhen the pump is full. Dry running will causedamage to the pump.

5.6 Final Control Check alignment of coupling acc. to chapter 5.3.1again. It must be possible to turn the unit easily byhand at the coupling.

6. Start-up, Operation, Shut down

The plant may only be started up by people whoare familiar with the local safety regulations andwith these Operating Instructions (especiallywith the safety regulations and safety instruc-tions given here).

6.1 Initial start-upBefore starting up the pump, check, if the followingpoints were controlled and carried out:� If pump is oil lubricated, first open oil drain (GD)

and drain off any liquid that may have collected(e.g. condensation). Close oil drain (GD) and fill oilas described in chapter 6.5.1.

� For pumps with grease lubrication, no further lu-brication is needed before initial start-up.

� Pump and suction pipe must be filled completelywith liquid when starting up.

� Turn pump unit once again by hand and checkthat it moves smoothly and evenly.

� Check that coupling guard is installed and that allsafety devices are operational.

� Switch on any sealing, flushing or cooling devicesthat are provided. See data sheet for quantity andpressure.

� Open valve in suction /intake pipe.� Set discharge side valve to approx. 25% of rated

flow quantity. With pumps with a discharge branchrated width less than 200, the valve can remainclosed when starting up.

� Secure, that unit is electrically connected acc. toall regulations and with all safety devices.

� Check direction of rotation by switching on and offbriefly. It must be the same as the directional ar-row on the bearing frame.

6.2 Switch on drive� Immediately (max. 10 seconds on 50 Hz resp.

max. 7 seconds on 60 Hz currency feed) afterreaching normal operating speed open dischargevalve adjust the required operating point. Thepumping data shown at the type plate resp. in thedata sheet and / or the order confirmation must be

met. Every change is only permitted after talkingwith the manufacturer!

Operation with closed valve in the suction and /or discharge piping is not permitted.

On starting-up without back-pressure, the back-pressure must be produced through throttling atthe discharge side. After reaching full back-pressure open valve

In order that the shaft sealing can be monitoredand maintained unhindered, no protection coveris provided in this area. Therefore special atten-tion is required when pump is working (no longhair, loose clothes, a.s.o.).

� Packing:

Packings need leakage for troublefree function(dropwise outlet of pumped medium). Adjust am-ple leakage in the beginning. Reduce that slowlyduring the first operating hours by continuouslyfastening of gland (see position "452" and"920.31" in sectional drawing) when pump is run-ning. Assume 30-100 drops / minute as approx.value.

Dry running packings harden and destroy theshaft sealing resp. the shaft.

If pump does not reach attended head or ifatypical sounds or vibrations do occur: Switch off pump (see chapter 6.7) and seek forcauses (see chapter 10).

6.3 Restarting Basically, the same procedure should be followed asfor starting up for the first time. However, there is noneed to check the direction of rotation and the acces-sibility of the pump unit. The pump should only be automatically restarted if ithas been made sure that the pump has remainedfilled whilst stand by.



Be particularly careful not to touch hot machineparts and when working in the unprotected shaftseal area. Remember that automatically con-trolled systems may switch themselves on sud-denly at any time. Suitable warning signs shouldbe affixed.

6.4 Limits of Operation

The operating limits of the pump / unit regardingpressure, temperature, performance and speedare shown in the data sheet and / or order con-firmation and must be observed under any cir-cumstances!

� Do not exceed the output given on the motor

name plate.� Avoid sudden changes in temperature (tempera-

ture shocks).� The pump and motor should run evenly and with-

out vibrations; check at least once a week.

6.4.1 Flow min. / max.If no other data are given in the curves or data sheets,the following is valid:

Qmin = 0,1 x QBEP for for short time operationQmin = 0,3 x QBEP for continuous operationQmax = 1,2 x QBEP for continuous operation *)QBEP = Flow in efficiency optimum*) on condition that NPSHfacility > (NPSHpump + 0,5 m)

6.4.2 Abrasive Media

On pumping liquids with abrasive componentsan increased wear at hydraulic and shaft seal-ing must be expected. The intervals of inspec-tion should be reduced compared to the usualtimes.

6.4.3 Permitted number of starts The permitted number of starts of the pump must notbe exceeded, see diagram 6.

1,0

10,0

100,0

1 10 100 1000

Motor power [kW]

max

. per

m. s

tarts

/h

diagram 6 With electric motors, the permitted number of starts isgiven in the attached motor operating instructions. If two different figures are given, the lower figure isvalid.

6.5 Lubrication of Bearings6.5.1 Oil lubrication

The bearing bracket must be filled up with oil.For quality of oil refer to chapter 7.4.1. For qantity of oil refer to chapter 7.4.1. The pumps are delivered without oil filling!

Oil level sight glass (standard design)Remove oil filling plug (637) and fill oilinto the connection opening (GF1).Fill in oil up to the middle of the oil levelsight glass (642) (pic 7). Keep level ex-actly. Overfilling leads to increasedbearing temperature and possibly oilleakage. If oil level is too low this cancause shortcoming of lubrication.

pic 7

Constant level oiler (special design)� Supplied loose.� Unscrew the reservoir from the main body (right

threaded) and set aside.� Seal the main body into the bearing bracket (330),

through a PTFE sealing tape, at connection forconstant level oiler (638). Tighten until threadedboss is in vertical position (picture 8).

� Remove the oil filling plug (637) (upper side ofbearing bracket) and fill in oil through the connec-tion opening (GF1), until the oil level reaches al-most the middle of the oil level sight glass in themain body.

� Using a funnel, fill the reservoir (picture 8).� Make sure that o-ring is on reservoir spout.� Place thumb over reservoir spout, invert, and in-

sert the spout into the internal threaded boss onthe main body. Tighten reservoir (picture 8).

� Now the oil is flowing from the reservoir into thebearing chamber.

� Repeat filling till the reservoir stays full to 2/3rd.� Refill oil as soon as the oil level falls below 1/3rd.

pic 8

6.5.2 Grease lubrication

For quality of grease refer to chapter 7.4.2. For quantity of grease refer to chapter 7.4.2.

� The bearings are already filled with lithium based

grease at the factory and are thus ready for use.� The grease provided is suitable for a temperature

range from -30° to +90°C (measured at surface ofbearing bracket).



� Re-lubrication via the two grease nipples (636).� Bearing temperature (measured at bearing

bracket) should lie max. 50°C over ambient tem-perature and must not exceed 90°C, controlweekly at least. On grease lubrication the bearingtemperature can temporarily be higher by 5-10°Cafter regreasing, till a possible surplus of grease inthe bearings is cut.

6.6 Monitoring

In areas endangered to explosion it is recom-mended to monitor the temperature of thebearings and the vibrations of the bearingbracket.

Regular monitoring and maintenance will ex-tend the life of your pump or pump system.

� Check oil level at least once a week and top up ifnecessary.

� Check pump for leaks at least once a week.� On packing, check quantity of leakage at least

once a week (see chapter 6.2 section "Packing").� Check the regulating and monitoring devices of

any sealing, flushing or cooling systems once aweek to ensure that they function properly. Out-going cooling water should be handwarm.

� With double mechanical seals, monitor pressureand flow rate in mechanical seal area; check atleast once a week.

� Pumps which are exposed to corrosive chemicalsor to wear through abrasion must be inspected pe-riodically for corrosion or wear and tear. The firstinspection should be carried out after six months.All further inspection intervals should be deter-mined on the basis of the state of the pump.

6.7 Shutting down� Close the valve in discharge pipe right before

(max. 30 seconds) switching off the motor. This isnot necessary if there is a spring-loaded checkvalve.

� Switch off motor (make sure it runs down quietly).� Close the valve on suction side.� Close auxiliary systems. Do not shut down cooling

system until pump has cooled down.� If there is any risk of freezing, empty pump, cool-

ing areas and pipes completely.

� If the pump also remains under operating condi-tions (pressure and temperature) when station-ary,leave all sealing, flushing and cooling systemsswitched on.

� The shaft sealing must remain sealed if there is arisk of air being sucked in (in the event of supplyfrom vacuum systems or parallel operation withshared suction pipe).

6.8 Storage / longer periods of non-operation6.8.1 Storage of new pumpsIf the putting into operation shall happen a longer pe-riod after the delivery, we recommend the followingmeasures for the storage of the pump:� Store pump at a dry place.� Rotate pump by hand at least once a month.

6.8.2 Measures for longer putting out of operationPump remains installed and in ready for operation:� Test runs of 5 min. duration must be made in

regular intervals. The span between the test runsis depending on the plant. However, it should bemade once a week, at least.

6.8.3 Longer periods of non-operationAfter long stationary periods, packings mayhave hardened; these must be replaced beforestart-up. When starting up, follow the instructions forstarting up for the first time (see chapter 6)!

a) Filled pumps� Switch stand-by pumps on and immediately off

again once a week. Possibly use as main pump.� If the stand-by pump is at operating pressure and

temperature, leave all sealing, flushing and cool-ing systems switched on.

� Replace oil or grease after 2 years.� Stuffing box must be adjusted to maintain lubrica-

tion of the packing (e.g. do not over tighten).

b) Drained pumps� Turn shaft at least 1x week (do not switch on be-

cause of dry running).� Replace oil or grease after 2 years.

7. Servicing, Maintenance7.1 General remarks

Work should only be carried out on the pump orpump unit when it is not in operation. You mustobserve chapter 2.

Maintenance and servicing work must only becarried out by trained, experienced staff whoare familiar with the contents of these OperatingInstructions, or by the Manufacturer's ownservice staff.

Maintenance and servicing work must only becarried out by trained, experienced staff whoare familiar with the contents of these OperatingInstructions, or by the Manufacturer's ownservice staff.

7.2 Mechanical seals

Before opening the pump, it is essential thatyou note chapter 2 and chapter 8.

If the liquid being handled leaks out at the mechanicalseal, it is damaged and must be replaced.



Replacement of the mech. seal according to accom-panying "Mounting Instructions for Shaft sealing". 7.3 Stuffing boxes Stuffing boxes require constant maintenance, seechapter 6.2 section "Stuffing box". If the leakage ratecan no longer be set correctly, the packing is worn outand must be replaced in good time (increased wear onshaft sleeve). Replacement of stuffing boxes acc. toattached "Mounting Instructions for Shaft Sealing".

Because of the risk of accidents, addition ofpacking to pumps during operation or at oper-ating pressure or temperature is strictly forbid-den!

7.4 Lubrication and Change of Lubricant 7.4.1 Oil lubrication

Temperature atbearing

First oil changeafter ..... operat-

ing hours

All further oilchanges

after ..... operat-ing hours

up to 60°C 300 8760 *) 60°C - 80°C 300 4000 *) 80°C - 100°C 200 3000 *)

*) at least 1x year

In plants endangered to explosion the oilchangeing intervals must be kept under anycircumstances!

Oil changing� After the first ....... operating hours, drain oil (oil

drain "GD" with drain plug 903.51) and flush withfresh oil. Clean oil drain plug and close oil drainagain.

� Fill in new oil according to chapter 6.5.� If the pump is left idle for a longer time, the oil

should be changed after two years.

Old oil must be disposed of in accordance withthe valid national environmental regulations.

Oil quality

Name

Lubricating oilCLP46

DIN 51517 or HD 20W/20 SAE

Symbol acc. DIN 51502 Kinematic viscosity at 40°C Flash point (acc. to Cleveland) Setting point (Pourpoint) Application temperature *)

46 ±4 mm2/s +175°C -15°C

higher than per-mitted bearingtemperature

*) For ambient temperatures under -10°C an other suitable type oflubrication oil must be used. Request required.

Oil quantity

Bearing bracket Oil quantity in l

24 0,5 32 1,1 42 1,4 48 1,7

7.4.2 Grease lubricationRe-greasing� Grease lubricated bearings with the possibility of

re-greasing must be re-lubricated all 4000 operat-ing hours, but at least 1x year. Clean lubricatingnipples (636) first.

Quality of grease lubricant ...... corresponding to NLGI GRADE 2

Quantity of re-greasing (approx. value)Bearing bracket bearing at pump

sidebearing at drive

side24 9g / 10cm3 14g / 16cm3

32 13g / 15cm3 20g / 22cm3

42 18g / 20cm3 33g / 35cm3

48 23g / 26cm3 42g / 46cm3

� If the pump is left non-operational for a longertime, the grease in the bearings should bechanged after 2 years.

7.5 Coupling Check the clearance in the coupling componentsregularly approx. every 1000 operating hours, but atleast 1x year, the radial clearance in the coupling partsmust be checked. For couplings with rubber pads the following applies: Unless a clearance in the couplings is necessary, thecoupling pads may wear out to approximately ¼ oftheir usual thickness, before they have to be changed.To measure the clearance in the coupling place amark on the O.D. of each coupling hub (see followingpic). Then fixing one hub, turn the opposite hub as faras possible. Then measure the distance (∆SV) be-tween the marks of the coupling. If this measure ex-ceeds the value given in the chart, the packings mustbe replaced. They must be replaced in sets.

Size 80 95 110 125 140 160 180 200 225 250 280 315 350 400

∆Sv [mm] 5,0 6,0 7,0 8,0 8,5 8,0 8,0 8,5 9,0 10,0 11,5 10,5 11,5 13,0

If wear is heavy, it must be assumed that themotor is not properly aligned with the pump orthat the distance between the coupling sectionshas changed. Replace worn elements and re-install or adjust coupling, as described in chap-ter 5.3.

7.6 Cleaning of pump The pump must not be cleaned with pressur-ised water - water will get into the bearings.



� Dirt on the outside of the pump has an adverseeffect on transmission of heat. The pump shouldtherefore be cleaned with water at regular inter-vals (depending on the degree of dirt).

� Radial-Shaft sealings (421.41 and 421.51) are notcompletely free from leakage. Impurities couldcause leakage at the shaft sealing area of theframe. Therefore wipe off impurities with a ragfrom time to time.

� Replace dirty oil level sight glass (642).

8. Dismantling and repair of pump8.1 General remarks

Repair to the pump or pump system may onlybe carried out by authorised skilled personnel orby the manufacturer´s specialist staff.

When disassembling the pump pay attention tochapter 2 and chapter 4.1.

For mounting and repair you can order specializedpersonnel if you want.

If dangerous liquids are pumped the appropriatedisposal of the handled liquid is necessary be-fore the disassembly of the pump. Pay attentionto the fact, that even in drained pumps there areremainders of the handled liquid. If necessarythe pump must be flushed or decontaminated.Laws must be observed, otherwise danger tohealth is existing!

� Before the disassembly the pump has to be se-

cured in such a way, that it can´t be started.� The pump casing must be drained and without

pressure.� All locking devices in the suction- and discharge-

pipe must be closed.� All parts must have taken on the temperature of

the environment.

Secure disassembled pumps, units or singleparts against tipping over or rolling off.

While disassembling the pump use of an openflame (blowlamp, etc.) only, when there is nodanger of setting fire, cause an explosion orcause injurious vapours. Never apply heat to remove the impeller nut.Use of heat may result in severe physical injuryand property damage.

Use original spare parts only. Pay attention tothe right materials and the matching design.

8.2 General

Works, which require shocks (hammer), mustonly be performed outside the explosive atmos-phere or only non-sparking tools must be used.

Carry out disassembly and mounting according to theappropriate sectional drawing.You will only need common tools.Before disassembly check if required parts are ready.Disassemble the pump only so far, as required for thereplacement of the repair part.

8.3 Disassembly of Back Pull Out Assem-blyThe Back Pull Out Assembly includes all parts of thepump except the volute casing (102V). As the pumpsare constructed for process design the volute casing(102V) can stay on the base frame and in the pipes,unless the volute casing itself must be repaired.� Drain volute casing (102V) through the drain plug

(912.11).� Unscrew pipe unions of all flush- and cooling-

water-pipes and drain lubrication oil from bearingbracket (330) via the screwed plug (903.51).

� Remove coupling guard.� Remove spacer of the spacer type coupling.� Loosen screws for support foot (183) from the

base frame.� Hang the Back Pull Out Assembly onto a lifting

device, so that it won´t sink down or press into thevolute casing during the dismounting. Examplesee picture 9 for lifting recommendations.

pic 9 � Loosen hexagen head bolt (901.11) from the cas-

ing.� Using the jack screws provided (901.42), separate

the Back Pull Out Assembly from the casing.

8.4 Removal of Impeller Note attached "Mounting Instruction for ShaftSealing".



� If the impeller has back vanes check the axialclearance "a" between the impeller (230) andcasing cover (161) before you continue the dis-mounting. Refer to sect. 8.7.1.

� Loosen impeller nut (922) (right threaded) by fixingthe rotor at the coupling end.

� Draw off the impeller (230) with two screw driversor pry bars (picture 10). Remove key (940.31).

pic 10

Be sure to locate pry bars under impeller vanesto prevent damage to the impeller.

� For further dismounting the Back Pull Out Assem-

bly should be placed in the vertical position (withvertical shaft, see picture 11). Attention: Precau-tions should be taken to prevent the Back Pull OutAssembly from tipping!

pic 11

8.5 Removal of Shaft Sealing� Before you remove casing cover notice "Mounting

Instructions for Shaft Sealing".� Unfasten hexagonal nut (902.32) (not available on

all pump sizes) and take casing cover (161) out ofbearing bracket (344).

8.6 Removal of Bearing� Remove coupling with a coupling puller (picture

12), remove coupling key (940.52).

pic 12

� Remove the flinger (507) axially by using 2 screwdrivers (see pic 13).

pic 13 � Loosen hexagen head bolt (901.41). Remove the

bearing bracket lantern from bearing bracket(330).

� Dismount circlip (932.51). Therefore you need asnap ring plier acc. to DIN 5256-C.

Bearingbracket

required snap ringplier

length i (min.) ofsnap ring plier

24 size 94/C 40 200mm32, 42 size 94/C 85 250mm

48 Größe 94/C 85 300mm

� Remove shaft (210) including anti-friction bearing(320.51 and 320.52) and bearing nut (923.51)from the bearing bracket (330).

� Remove the bearing nut (923.51). The bearing nutis right hand threaded and self locking. It can bereused 5 times if it is handled appropriately.

� Remove the anti-friction bearing (320.51 and320.52) from the shaft (210) using a hydraulicpress or a bearing puller.

8.7 ReconditioningAfter disassembly all parts must be cleaned andchecked for wear carefully. Worn or damaged partsmust be replaced by new parts (spare parts).When reassembling the pump it is recommended toreplace all seals.

All PTFE-sealing elements and graphite seal-ings are intended for being used only once.

In most cases it make sense, if damaged absolutelynecessary, to renew the mechanical seal and thebearings.Deposits on the impeller (230), in the volute casing(102V) or on the casing cover must be removed.



8.7.1 Clearance at impellerSuction side of impeller Back vanes of impeller

Drive side of impellerOnly for pump sizes

100-65-315125-80-315125-80-400125-100-315125-100-400150-125-315150-125-400200-150-315200-150-400

Nominal diameter D (mm) 6068 85

100120135

155175 220

min. 0,15 0,17 0,20 0,22 0,25 new max. 0,19 0,22 0,24 0,27 0,30 Radial clea-rance s (mm) wear limits 0,78 0,85 0,90 1,05 1,15

new 0,8 - 1,2 Axial clearan-ce a (mm) wear limits max. 1,7

When the wear limits has been reached or ex-ceeded, the worn parts must be replaced.

For volute casings (102V) with a wear ring (502.11)and cover casings (161) with a wear ring (502.31)there are the following possibilities to restore the cor-rect clearance:a) Renew impeller (230) and wear ring. Then the

original measures are restored.b) A customized wear ring (bored to fit) can be sup-

plied to avoid replacement of the impeller. Pleasecontact factory for details.

When volute casing (102V) or casing cover (161)without wear ring must be repaired, a wear ring can beinstalled to renew pump performance. Remachining ofthe volute casing and /or casing cover is required.Please contact the factory for details and assistance.

8.8 MountingRe-assemble the pumps using the reverse order ofsteps as completed for pump disassembly. Howeverthe following observations should be considered:� Pay attention to the utmost cleanliness when re-

assembling the pump.� For tight tolerances, e.g. between shaft sleeve

(433) and shaft (210) or impeller (230) and shaft(210), as well as thread, use a suitable anti-gallingcompound (e.g. Molykote/Never-Seeze), so thatthe assembly and the next disassembly will beeasier.

Anti-galling compound must be compatible withthe pumpage.

� Screws should be tightened, with the following

torque:

Screw torque in Nm Location Screw

Size Lubricatedthreads

Dry threads

M12 35 50 M16 105 150 Casing screws M20 210 305 M10 35 50 M12 60 90 All other screws M16 150 220

� Before mounting the second bearing on the shaft

push in the circlip (932.51) between the two bear-ings.

� Before mounting new bearings, warm them up to80°C in an oil bath or using a bearing heater. Ifnecessary use a tube to force the inner ring ontothe shaft by gentle taps with a hammer. Hold theouter ring to avoid vibrations of the balls.

� When bolting together the bearing bracket (330)with the bearing bracket lantern (344) and thebearing bracket lantern with the volute casing(102V), screws should be positioned in the centreof the drilled holes. Failure to do so could result inimproper oil setting.

� Push the flinger (507) onto the shaft (210) till itrests axially against the shoulder of the shaft.Between flinger (507) and Bearing bracket lantern(344) there must remain a clearance of at least0,7 mm.

� If necessary you can use a driver for mounting(see picture 14).

pic 14

� Do not use excessive force.� For mounting of the shaft sealing (packing or me-

chanical sealing) see separate description"Mounting Instruction of Shaft Sealing" and chap-ter 8.5.

� For impellers with back vanes the axial clearancebetween the back vanes and the casing cover(161) should be checked after mounting the im-peller (230) and tightening the impeller nut (922)(see chapter 8.7.1).

� After the mounting of the back pull out assembly,and its assembly into the volute casing, turn theshaft and control the free moving of the pump inthis way. The shaft sealings will cause slightly re-sistance when turning, but there must not be anycontact between metal parts.



� Before starting the pump check alignment of thecoupling. This can be dropped on pumps withspacer coupling, if pump casing and motor werenot disassembled.

Before starting the pump do not forget to fill inoil!

Before starting the pump do not forget to installand connect all security devices.

9. Recommended Spare Parts, Spare Pumps9.1 Spare Parts Spare parts should be selected to last for two-yearscontinuous operation. If no other guidelines are appli-cable, we recommend that you stock the number ofparts listed below (in accordance with DIN 24296). Number of pumps

(incl. stand-by pumps) 2 3 4 5 6/7 8/9 10/+

Spare Parts Number of Spare Parts Impeller 1 1 1 2 2 2 20% Wear ring 2 2 2 3 3 4 50%Shaft with key and nuts 1 1 1 2 2 2 20%Ball Bearing set 1 1 2 2 2 3 25% Shaft sleeve 2 2 2 3 3 4 50% Lantern ring 1 1 2 2 2 3 30% Packing ring 16 16 24 24 24 32 100%Joints for pump casingsets 4 6 8 8 9 12 150%

other joints sets 4 6 8 8 9 10 100%Mech. Seals set 1 1 2 2 2 3 25% Bearing (lantern withbearing bracket, com-plete with shaft, bear-ings, aso.)

- - - - - - 2

To ensure optimum availability, we recommendthat suitable quantities of spare parts are held instock, especially if these are made from specialmaterials and in the case of mechanical seals,because of the longer delivery times.

Spare Parts Order When ordering spare parts, please supply the follow-ing information: � Type: ______________________________________________________________________ � S/N (Order No.): ____________________________________________________ � Part name: _____________________________________________________________

� Sectional Drawing __________________________________________________

All the information is given in the data sheet and therelevant sectional drawing.

Store spare parts in dry and clean rooms!

9.2 Stand-by pumps It is essential that a sufficient number of stand-by pumps are kept ready for use in plantswhere failure of a pump could endanger humanlife or cause damage to property or high costs.Regular checks should be carried out to ensurethat such pumps are always ready for use (seechapter 6.8).

Store stand-by pumps according to chapter 6.8.

10. Faults - Causes and Solutions The following notes on causes of faults and how torepair them are intended as an aid to recognising theproblem. The manufacturer's Customer Service De-partment is available to help repair faults that the op-erator cannot or does not want to repair. If the opera-tor repairs or changes the pump, the design data onthe Data Sheet and chapter 2 of these Operating In-structions should be particularly taken into account. Ifnecessary, the written agreement of the manufacturermust be obtained.



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Cause Solution ■ Back-pressure too high

check facility for pollution, open discharge valvereduce resistance in discharge pipe (e.g. clean filter if neces-sary)use larger impeller (note available motor power)

■ ■ ■ Back-pressure too low, discharge too low throttle discharge valve ■ ■ Speed too high reduce speed

compare speed of motor with specified pump speed (ratingplate)when adjusting speed (frequency transformer) check refer-ence value setting

■ ■ Speed too low increase speed (check available motor power)compare speed of motor with specified pump speed (ratingplate)when adjusting speed (frequency transformer) check referencevalue settings

■ ■ ■ ■ Flow too little increase min. flow (open discharge valve, bypass) ■ Flow too big reduce flow (throttle discharge valve) ■ ■ Impeller diameter too big use smaller impeller ■ ■ Impeller diameter too small use larger impeller (check available motor power) ■ ■ ■ ■ Pump and/or pipes not completely filled with liquid fill

vent ■ ■ ■ Pump or suction/intake pipe blocked clean ■ ■ Air pocket in pipeline vent

improve course of pipe ■ ■ ■ ■ ■ Suction height too big / NPSH of system too small

increase liquid level and admission pressurereduce resistance in the intake/suction pipe (change courseand rated width, open shut-off valves, clean filters)

■ ■ ■ Air being sucked in increase liquid levelcheck if suction pipe is vacuum-tight

■ ■ ■ Air being sucked in through shaft sealing clean sealing pipeincrease sealing pressurereplace shaft sealing

■ ■ Direction of rotation is wrong swap over two phases of power supply (to be done by anelectrician)

■ ■ ■ ■ Inner components suffering from wear replace worn parts ■ ■ ■ Density and/or viscosity of liquid handled is too high seek assistance ■ ■ Stuffing box not straight tighten evenly ■ Stuffing box is fastened too tight resp. shaft sealing is worn loosen stuffing box

replace packing and/or mechanical sealcheck sealing, flushing and cooling pipes (pressure)avoid dry running

■ ■ Lines and roughness on shaft or shaft sleeve replace parts ■ ■ Unsuitable packing material use suitable material (check shaft or shaft sleeve for damage

beforehand) ■ ■ Deposits on mechanical seal

cleanreplace mechanical seal if necessaryif necessary provide additional rinsing or quench

■ ■ Impeller out of balance

remove blocks/depositsreplace impeller if broken or unevenly worncheck shafts to ensure that they are running true

■ ■ ■ Coupling not aligned align pump unit better ■ ■ Coupling distance too small change ■ ■ ■ ■ ■ Forces in pipeline too high (pump unit under strain) change (support pipes, use compensators, etc.)

is foundation plate/frame properly cast in place? ■ Too much, too little or the wrong type of lubricant change ■ Electricity supply not right (2-phase running) check voltage of all phases

check cable connections and fuses ■ Sealing insufficient tighten screws

replace sealing ■ ■ Bearing damaged replace

check lubricant and bearing space for pollutants (rinse oil area) ■ Relief fittings insufficient

clean relief openings in impellerreplace worn parts (impeller, split rings)adjust in line with the system pressure/intake pressure given onordering

■ System-related vibrations (resonance) seek assistance

Pumpenfabrik ERNST VOGEL GmbHErnst Vogel-Straße 2 E-Mail: [email protected] Stockerau Internet: www.vogel-pumps.comTelefon: (+43) 2266 / 604 www.hydrovar.comFax: (+43) 2266 / 65311

mailto:[email protected]

http://www.vogel-pumpen.com/

http://www.hydrovar.com/

Installation, Operation and Maintenance Instruction · 3.3 Bearings.....7 3.4 Approximate Value for...

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Transcript of Installation, Operation and Maintenance Instruction · 3.3 Bearings.....7 3.4 Approximate Value for...