OIM_DBSA

Range: DBS Non – clogging volute casing pump PUMP DESCRIPTION: ______________________________ SERIAL NUMBER: ____________________

For local contact details: www.sterlingfluidsystems.com

In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its

products at any time without prior notice

� (Sterling Fluid Systems BV) 2003

Operating instructions Safety issues Chapter 1 Safety instructions and compliance Intended application Chapter 2 Application, description

Planning the installation Chapter 3 Requirements, piping system, accessories

Unpacking, storage, transport Chapter 4 Supply, interim storage, corrosion protection

Installing the pump Chapter 5 Assembly at site, tools, checks

Start-up and shut-down Chapter 6 Important requirements

Maintenance, dismantling, assembly Chapter 7 Intervals, cleaning

Troubleshooting Chapter 8 If something does not work

Technical data Chapter 9 Dimensions, permissible values Annex Chapter 10 Connections, dimensions table, sectional drawings, specific operating limits Attention: Both the pump and/or the pump set must be installed and commissioned by qualified technical personnel only and these installation, commissioning and operating instructions must be strictly observed. Failure to do so could result in:

�� danger to you and your colleagues, �� the pump or the pump unit may be damaged,

Note that the manufacturer is not liable for damages resulting from failure to observe these instructions. Please be aware of your responsibility to your colleagues when working on the pump or the pump set!

Safety instructions marked with have to be considered in particular when operating this pump in potentially explosive atmospheres!

Safety issues Page 1 of 3 Chapter 1



products at any time without prior notice.


1. Safety issues 1.1 Safety instructions This manual gives basic instructions which must be observed during installation, operation and maintenance of the pump. It is therefore imperative that this manual be read by the fitter and the responsible personnel or operator prior to assembly and start up. It must always be kept available at the installation site. Within this manual, safety instructions are marked with safety symbols.

Safety symbol to ISO 3864-B.3.1

This general hazard symbol highlights information non-compliance with which could cause a risk to personal safety.

Safety symbol to ISO 3864-B.3.6

This symbol refers to electrical safety. This word gives warning of a hazard to the ma-chine. Safety instructions that have to be considered when operating this pump in potentially explosive atmospheres are marked with the word:

Signs affixed to the machine, e.g. �� arrow indicating the direction of rotation �� symbols indicating fluid connections must be observed and kept legible. 1.2 Qualification and training of operating personnel The personnel responsible for operation, maintenance, inspection and assembly must be adequately qualified. The responsibilities of the operating personnel must be exactly defined by the plant operator. If the staff do not have the necessary knowledge, they must be trained and instructed, which may be performed by the machine manufacturer or the supplier on behalf of the plant operator, if required. Moreover, the plant operator is to make sure that the contents of this manual are fully understood by the operating personnel and other relevant personnel such as maintenance staff. 1.3 Hazards in the event of non-

compliance with the safety instructions

Non-compliance with the safety instructions may cause a risk to the personnel as well as to the environment and the machine and may result in a loss of any right to claim damages. For example, non-compliance may involve the following hazards: �� failure of important functions of the equipment �� failure of specified maintenance and repair

procedures

CAUTION






�� electrical, mechanical and chemical hazards affecting personal safety

�� release of environmentally damaging substances

1.4 Safety at work When operating the pump, the safety instructions contained in this manual, the relevant national accident prevention and explosion protection regulations and any other service and safety instructions issued by the plant operator must be observed. 1.5 Safety instructions relevant to operation �� If hot or cold machine components involve

hazards, the customer must ensure these components are guarded against accidental contact.

�� Contact guards for moving parts (e.g. coupling) must not be removed from the machine while in operation.

�� Any leakage of hazardous (e.g. explosive, toxic, hot) fluids (e.g. from the shaft seal) must be drained away so as to prevent any risk to personal safety or the environment. Statutory regulations must be complied with.

�� Hazards resulting from electricity must be prevented. Local regulations must be complied with.

1.6 Safety instructions relevant for maintenance, inspection and assembly work It shall be the plant operator's responsibility to ensure that all maintenance, inspection and assembly work is performed by authorised and qualified personnel who have adequately

familiarised themselves with the subject matter by studying this manual in detail. Any assembly or maintenance work on the machine shall only be performed when it is at a standstill. The procedure for stopping the machine described in this manual must be followed. Pumps which handle hazardous fluids must be decontaminated. On completion of work all safety and protective facilities must be re-installed and made operative again. Prior to restarting the machine, the instructions listed under sub-section "Checks before first start-up" must be observed. 1.7 Safety instructions for the use in

areas with explosion hazard In this paragraph information are given for an operation in areas with explosion hazard. 1.7.1 Arrangement of the units If the pump is completed with other mechanical or electrical components to one unit, the complete unit may be considered only as device category according to the directive 94/9 EC which is fulfilled by all used components. The operator has always to pay attention to the conformity of all used components of the pump unit with the directive 94/9 EC. 1.7.2 Execution of coupling guards for shaft

couplings Coupling guards which shall be used in areas with explosion hazard have to fulfil the following criteria:






�� do not use sparking material e.g. brass or steel plate constructions executed this way that with faults to be foreseen (e.g. deformation by stepping on the coupling guard) a contact between the rotating parts and the coupling guard is excluded.

1.7.3 Belt-driven pump sets �� The belts must include some electrically

conductive material. �� The belt-driven pump sets must always be

earthed. �� The condition of the belts must be checked

regularly. 1.7.4 Priming of the pump The pump is assumed to be filled with liquid at all times during operation so that no explosive mixtures can form inside the pump and dry operation of the mechanical seal is prevented. 1.7.5 Avoidance of exterior impact effect The operator has to ensure that with an operation of the machine in areas with explosion hazard no exterior impact effect to the machine casing may arise. 1.8 Unauthorised alterations and

production of spare parts Any modification to the machine is permissible only within the limits as documented by Sterling Fluid Systems or after consultation with Sterling Fluid Systems. Using genuine spare parts and accessories authorised by the manufacturer is in the interest of

safety. Use of other parts may exempt the manufacturer from any liability. 1.9 Unauthorised use The reliability of the pump delivered will only be guaranteed if it is used in accordance with this manual. 1.10 Warranty / guarantee Sterling Fluid Systems guarantee satisfactory operation if: �� the pump is installed and operated in

compliance with these instructions and in operating conditions approved by Sterling Fluid Systems

�� modifications are only undertaken with Sterling Fluid Systems’ written agreement.

Intended application Page 1 of 3 Chapter 2

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

Sterling Fluid Systems reserves the right to modify its



2. Intended application 2.1 General advises

�� Observe the pump operating limits docu-mented by Sterling Fluid Systems (if there is any doubt, please contact Sterling Fluid Systems).

�� According to directive 94/4 EC equipment

group II, category 2, is applicable to the pump. The nameplate bears the marking �x II 2G T1-T5

�� The operator is to ensure the permissible maximum temperature of the liquid handled as a function of the temperature class is not exceeded. Specific limitations or restrictions resulting from pump design or mode of operation must be taken into consideration (see annex). Otherwise temperatures in excess of the temperature of the pumped liquid may occur on the pump casing which could be hazardous to personnel and environment if the pump is operated in a potentially explosive atmosphere.

�� If the pump is operated in a potentially explosive atmosphere of temperature class T4, the ambient temperature must not exceed 40 °C (see also 5.2.2).

2.2 Design and mode of operation DBS pumps process type are horizontal, single-stage volute-casing, free-flow impeller or two channel impeller or three channel impeller with dimensions correspond to a large extent to those of the ISO2858/EN22858. The process construction allows the withdrawal of the complete pull-out unit, without the need of removing the pump casing from the pipework. Series DBS volute-casing pumps can be used where the requirement is for pumping dirty liquids or liquids with solids, such as: �� Sewage plants �� Chemical plants �� Rolling mills �� Foundries, iron and steel works �� Construction industry �� Paper and cellulose pulp industry �� Sugar mills �� Food industry

CAUTION








2.3 Product identification The pump identification on the nameplate covers all essential constructional features Position Characteristic Code Explanation

1-3 Type DBS

Horizontal, single - stage volute pump of process type

4 Construction A

5-9 Size Impeller diameter

032 – 300 16 – 50

Diameter of discharge nozzle in mm

Diameter of impeller in cm

10 Impeller type D Z F

Triple channel impeller

Double channel impeller

Free-flow impeller

11 Hydraulic A

12 Bearing B C S T

Pump side: one cylindrical roller to DIN 5412 Motor side: 1 deep groove ball bearing. Grease lubricated

Motor side: 1 deep groove ball bearing. Oil lubricated

Motor side: Two single-row angular contact ball bearings paired. Grease lubricated

Motor side: Two single-row angular contact ball bearings paired. Oil lubricated

13-15 Shaft sealing 051 052 071 BKS BKW

Uncooled stuffing box, sealing fluid outside source, flushing

Uncooled stuffing box, sealing fluid from an outside source

Uncooled stuffing box with flushing up-stream of packing and flushing between wear plate and impeller

Burgmann mechanical seal MG1-G60-Q1Q1VGG

Burgmann mechanical seal MG1-G60-Q1Q1PGG

16-17 Material 0B

0E 4B

Main parts, and impeller made of cast iron GG 25

Main parts of cast iron GG 25, impeller made stainless steel

Main parts, and impeller made of stainless steel (1.4408)

18 Casing design B C

With wear plate

Without wear plate

19

20








Example pump designations:

1-3 4 5-7 8-9 10 11 12 13-15 16-17 18

DBS A 200 32 D A S 051 0B B The fifteenth letter of the pump designation signifies the material combination of the mechanical seal where applicable.

CAUTION If the designation of the shaft seal cannot be found in chapter 2.3 or if the designation is indicated by the letters QQQ, please see instructions in the data sheet.

2.4 Nameplate In the event of queries, please provide the following information as noted on the nameplate: �� Product identification �� Serial number 2.5 Accessories The accessories provided with the pump are indicated on the order acknowledgement. Accessories subsequently installed by the operator must not impair pump function or safety

Materials of construction Shaft seal

Hydraulic

Ø impeller cm. Nominal Ø delivery branch Estate constrictive Pump designation

Impeller type

Casing design

Bearing lubrication

Planning the installation Page 1 of 3 Chapter 3






(Sterling Fluid Systems BV) 2003

3.0 Planning of the installation

3.1 Pipework

CAUTION

• Suction branch axial, discharge branch radially

upwards.

• The diameters of the piping are not determined

by those of the pump delivery and suction

branches. On short delivery pipe resistance

constitutes but a small portion of the delivery

head. For long pipe runs the most economic

pipe diameter must be assessed in each

particular case.

• Make sure that the flange gaskets do not

protrude into the bore.

• Make sure that the piping is cleaned before

installing the pump.

• Support the piping in such a way that it is free

of stress (danger of breach of pump parts).

Once the flange bolts have been loosened, the

flanges must not yield more than the amount

corresponding to the gasket thickness, nor

must they be cut of parallel nor bear against

each other under stress.

• Avoid abrupt changes of the pipe cross-

sections and changes of direction.

• Connect different nominal diameters with an

eccentrically taper piece. Thus, the formation

of air pockets in the piping will be avoided.

• Unfavourable installed pipe runs, especially on

the suction side (i. e. bends in various planes

immediately before the suction branch) can

affect the performance of the pump.

• The flow velocity in the piping not be less than

1 m/sec because otherwise there is the danger

of sedimentation.

3.1.1 Suction or feed line

Feed line. To prevent collection of air or gas the

feed line must be horizontal or show a gradual

slope towards the pump

Suction line. Since the pump is not of the self

priming type and a foot valve cannot be used in

the case of contaminated liquid, can be started

only after prior evacuation (evacuating unit). The

suction line must be horizontal or rise

continuously all the way to the pump.

Feed operation suction operation

When handling a fluid containing gas, a suction

head of at least 0,5 m. should be available to the

pump, since the under pressure at the entry of the

impeller would otherwise cause a separation of

gas and a loss prime.

The bore of the feed or suction pipe should be set

as deeply as possible below the suction side liquid

level. In case the bore should face downwards it

must, however, be so far away from the bottom

that the inlet losses will not become too great,

thus reducing the delivery performance.

When delivery sludge, we recommend to lay the

suction line horizontal, preferably immediately at

the bottom of the suction side collecting tank

(figure 1ª). The suction line should be as short as

possible.








The isolating valves in the suction or feed line

must remain fully open during operation. NEVER

use this valves for regulating. If possible, isolating

valves in the suction line should be mounted with

the spindle in horizontal position to avoid air

pockets forming in the spindle cap. To avoid

ingress of air, it is advisable to use isolating

valves with sealing water connection or with water

seal.

3.1.2 Delivery line

Install a gate valve in the delivery line close to the

pump branch. It is recommended to install a non-

return valve between pump branch and regulating

valve, thus protecting the pump against reverse

rotation and water hammer which may occur in

the piping in case of sudden shut-down of the

pump.

3.1.3 Inlet and outlet connections

(see also arrangement drawing)

The various connecting points are shown in

Chapter 10.

3.1.3.1 Sealing liquid connection Xa,b

(a = inlet, b = outlet)

At Xa a sealing liquid line is normally connected

up. The pressure of the connected clear liquid

should be about 1 bar higher than the maximum

operating pressure of the pump (pump delivery

branch, pressure gauge connection I). The sealing

water prevents abrasive particles contained in the

delivery liquid from entering the stuffing box, thus

avoiding premature wear of the shaft sleeves

under the stuffing box packing. When delivering

raw sewage or storm water, an automatic grease

gun may olso be provided for sealing purposes.

When delivery biologics sludge or liquids without

abrasive additions under suction head conditions,

no sealing is required. Whilst sealing by a clean

liquid is necessary when handling raw sludge,

putrid sludge or pasteurised sludge and liquids

with abrasive additions, as well as, in the case of

operation under suction lift conditions.

The pipe running to this connection Xa should

incorporate a pressure reducing valve, if the

pressure in the mains line is far above the

required one. In order to keep the sealing water

consumption as low as possible, we recommend

to install a magnetic valve which will be opened

during pump operation only.

3.1.3.2 Flushing liquid connectionXXIIIa

For special applications of delivery liquids with a

very high content of solids or tendency towards

crystallisation this connection can be additionally

drilled. Besides, the lantern ring will then be

situated at the bottom of the stuffing box chamber.

The flushing liquid is taken directly to the shaft

sleeve before the packing, thus preventing the

entry of solids between stuffing box packing and

shaft sleeve.








3.1.3.3 Flushing liquid connectionXXIIIb

Here the suction side clearance gap between

wear plate and impeller can be flushed, if required

– especially when pumping strongly contaminated

delivery fluids.

3.1.3.4 Leakage water connections IX

The leakage line must be sized amply enough forthe liquid to flow off freely. It should be designedso that it can be cleaned easily.

3.1.3.5 Pressure gauge connection I

Vent III

Drain VII

Please, see connection dimensions drawing.

3.2 Electrical connections

The electrical connection for the driving motor

must comply with the relevant local rules and

requirements.

Unpacking, storage, transport Page 1 of 2 Chapter 4







4. Unpacking, storage, handling

4.1 General advises

• Do not lift heavy equipment overhead of

personnel.

• A safe distance must be kept when lifting and

moving the equipment.

• Use only approved and suitable lifting equip-

ment.

• The length of the lifting equipment should be

such that the pump or the set are lifted in hori-

zontal position.

• Do not attempt to lift the pump or the pump set

using eyebolts on pump components.

• Do not remove protection covers from the

pump branches, as they prevent contamination

of the pump.

4.2 Unpacking

Do not unpack the pump until it has been carefully

checked for damage that may have occurred in

transit. Report any damage on the counterfoil or

delivery note.

Claims must be made immediately on the carrier

or the transport insurance.

4.3 Intermediate storage

If the pump or the pump set is not to be installed

immediately it should be stored in a dry and vibra-

tion-free room.

The packing should be checked for damage on a

monthly basis.

4.4 Handling

The pump or the pump set must be lifted as

shown below:

Pump without motor

Pump unit

4.5 Protection against corrosion

4.5.1 Removal of protection

In general, a preservation coating is only applied

to 0B and 0E pump material executions.

CAUTION

Unpacking, storage, transport Page 2 of 2 Chapter 4







To remove the preservative coating, the pump

should be filled and drained several times using

appropriate agents, e.g. solvent naphta, diesel oil,

or an alkaline detergent. Flush with water, if

necessary.

The pump must be installed and put into operation

immediately afterwards.

4.5.2 Renewing corrosion protection

If the pump has been supplied preserved and is to

be stored, a new preservative coating should be

applied after six months.

For suitable preservatives, contact Sterling Fluid

Systems.

Installing the pump Page 1 of 3 Chapter 5







5. Installing the pump

5.1 General advises

• The foundation of the pump must be level and

have a minimum of vibration. It is recom-

mended to use a baseplate.

• Concerning the pipework, the pump must not

be considered as a fixpoint.

• Care should be taken that the pipework forces

and moments acting on the pump branches do

not exceed the permissible pump branch loads

acc. to ISO 5199 (see chapter 9).

• The pump must be properly aligned

• The pipework must be properly installed.

• Incorrect pump installation or alignment will

lead to an overload on the machine which

could be hazardous to personnel and

environment if the pump is operated in a

potentially explosive atmosphere.

• Leakage due to improper pipe or supply line

connections may lead to the formation of

explosive mixtures and be hazardous to the

personnel and the environment if the pump is

operated in a potentially explosive atmosphere.

• The coupling must be installed, started-up and

operated in accordance with the operating

instructions of the coupling manufacturer.

Misalignment of the coupling may result in

inadmissible temperatures at the coupling and

pump and motor bearings. It has to be

ensured, that the half couplings are correctly

aligned at all times.

5.2 Prerequisites

Only appropriately trained staff must undertake

the work described in this chapter.

5.2.1 Fitting tools

Standard tools and lifting equipment are used.

These should be available at the customer's end.

5.2.2 Permissible environment

The ambient temperature range should be from

-20 °C to +60 °C (for restrictions see also chapter

2).

The atmospheric humidity should be low in order

to avoid corrosion.

5.2.3 Space utilisation

The space required by the pump or the pump set

can be seen from the attached table of dimen-

sions or the arrangement drawing.

Clear and easy access to the shut-off and regu-

lating valves and the measuring instruments must

be ensured.

5.2.4 Installation position

DBS pumps are installed in horizontal position.








5.2.5 Preparatory checks

The following checks should be made prior to

installation:

− ease of running (check that the shaft is free to

rotate by hand)

− direction of rotation of the motor

− shut-off valve in the suction or feed line and

regulating valve in the discharge line must be

closed

− power to the equipment must be disconnected

5.2.6 Alignment of the pump set

After aligning the set the axial clearance between

the two coupling halves measured at one point of

the coupling must be the same over the complete

circumference of the coupling, the permissible

tolerance being ± 0.05 mm.

Carry out the radial alignment of the coupling

using a bevelled straight edge and a feeler gauge.

Aligning the coupling clearance

The indications given before are general rules.

Always the operation instruction of the coupling

manufacturer must be considered.

5.2.7 Pumps with V – belt drive

Please, follow the instructions of the V – belt

manufacturer.

5.3 Foundation

5.3.1 Placing the pump set Prior to placing the pump set on the foundationwhich should be well set, the following preparatorywork must be carried out:

− check the dimensions of the foundation

− roughen and clean foundation surface

− remove shuttering/cores from the anchor holes

− blow the anchor holes clean

− check the positions and dimensions of the

anchor holes against the arrangement drawing

The complete set mounted on the baseplate must

be placed on the foundation with its foundation

bolts suspended.

− Place shims under the baseplate on both sides

of the foundation bolts, 10 mm from the base-

plate edge

− Use a spirit level to align the set

− If necessary, place shims between the founda-

tion bolts to prevent the baseplate from sag-

ging. Care should be taken to minimise distor-

tion of the baseplate during installation

− The foundation bolts should be embedded in

concrete using quick-setting grout

− Tighten the nuts of the foundation bolts cross-

wise (when the grout is set)

− Re-check the alignment with a spirit level

• Care should be taken at every check that the

axial play of the pump rotor is taken into con-

sideration.

• Avoid distortions when finally tightening the

bolts.

CAUTION








5.3.2 Grouting the baseplate

Prior to grouting the baseplate, carry out the fol-

lowing preparatory work:

− Check the dimensions with regard to height

and adjustment of flanges

− Re-adjust baseplate, if necessary

Ram earth-humid concrete under the baseplate or

add shrinkage-free grout until the entire space

under the baseplate is filled. Grouting should be a

continuous process so as to ensure that no air

pockets are left.

When the grout is set re-tighten the foundation

bolts and re-check the alignment of the coupling.

5.4 Pump installation in the piping

system

− Remove the protection covers from the pump

flanges and the auxiliary pipeline connections

− Correctly insert the flange seals

− Connect the suction or feed line

− Connect the discharge line

5.5 Hydrostatic test

• For the hydrostatic test of pressure containing

pump parts (casing, casing cover), a maximum

pressure of 1.5 x nominal pump pressure

should be applied.

• If the piping system is to undergo a hydrostatic

test, the pump must be excluded from such

testing.

5.6 Cleaning, flushing and pickling ofthe pipework

When the pipework is cleaned, flushed or pickled,

the pump should be excluded.

Starp-up and shut-down Page 1 of 3 Chapter 6




� (Sterling Fluid Systems) 2003

6. Start-up and shut-down operations

6.1 General advises

�� Observe the pump operating limits documented by Sterling Fluid Systems (if there is any doubt, please contact Sterling Fluid Systems).

�� Safety measures should be taken at the customer's end to ensure (for example by means of a relief valve) that the permissible pump casing pressure is not exceeded during operation.

�� If the liquid handled is hot, the pump must be filled slowly so as to avoid distortions or heat shocks.

�� The flowrate must be changed at constant speed only on the discharge side. During operation the shut-off valve in the suction or feed line should always be kept open, in order not to run the risk of cavitation.

�� Do not run the pump with the regulating valve closed for any length of time, if there is no bypass line (for restrictions, see also annex).

�� The operator is to ensure the permissible

maximum temperature of the liquid handled as a function of the temperature class is not exceeded. Specific limitations or restrictions resulting from pump design or mode of operation must be taken into consideration (see annex). Otherwise temperatures in excess of the temperature of the pumped liquid may occur on the pump casing which could be hazardous to personnel and environment if the pump is operated in a potentially explosive atmosphere.

�� The operator is to ensure that a dry operation of the shaft seal is prevented. For pumps equipped with packing, the gland be tightened until there is a slight leakage and are only allowed to be operated when primed. Pumps with a single-acting mechanical seal are only allowed to be operated when primed. For pumps equipped with double-acting mechanical seal, also the seal chamber must be flushed or sealed.

�� If the operator cannot warrant this condition, appropriate monitoring devices must be used. Improper installation (e.g. vertical installation) may impair the self-venting properties of the seal chamber, so that gas bubbles may be collected in the pump and cause the mechanical seal to run dry.

�� High negative pressure on the suction side (e.g. due to clogged suction-side strainers or low system pressure) may result in air intake at the shaft seal forming gas bubbles in the pump. This may also cause the mechanical seal to run dry. Suitable monitoring facilities shall be installed, if necessary.

�� The direction of rotation of the motor is only allowed to be checked with the pump primed (for pumps with packing and single-acting mechanical seal) and, also, with flushed or sealed seal chamber.

6.2 Electrical connections The motor has to be connected according to the scheme in the terminal box. 6.3 Control before first start-up Check the following points before start-up: 1. Are all the pipes connected and the

connections tight? 2. Are pumps and pipework orderly filled?






3. Is the control valve in the discharge line closed?

4. Is the isolation valve in the suction or feed line entirely open?

5. Is the motor ready for operation? 6. Is the direction of rotation of the motor

correct? (Check by short start of the motor) 7. Has the coupling been aligned properly?

(see 5.2.6 ) 8. If there is a shaft sealing supply line, is it

entirely open? 9. Is the bearing housing correctly filled with

oil? (see 7.4.1) 6.4 Start-up For the start-up, proceed as follows: 1. Entirely open the isolating valve in the

suction or feed line. 2. If existing, entirely open the valves of the

shaft sealing supply line. 3. Close the discharge valve. 4. Start motor. 5. Check the manometer at the pressure

gauges. If the pressure does not build up continually with increasing number of revolutions, turn off motor and de-aerate the pump once more

6. Once the pump has reached the operating, revolution regulates the point of operation by using the discharge control valve (admissible operating conditions see data sheet, annex).

Avoid the maximum casing pressure to be exceeded due to system failure by means of safety measures on the installation side (e.g. overflow valve). An alteration of the service duty, which might necessary may be effected by throttling with the gate valve in the delivery line, to the extent warrantable taking into account the risk of clogging due to the nature of the liquid.

On pumps, which are driven via V – belts the speed and thus the performance can be changed by altering the transmission ratio. The coupling alignment should be re-checked when the pump has reached the operation temperature. If necessary, pump or driver has to be re-aligned. 6.5 Operation 6.5.1 Switching frequency For a start with the regulating valve closed or slightly opened and for uniform start-stop intervals, the following numbers of switching actuations apply:

P kW max switching frequency equally spaced per hour

< 12 12 < P <100

>100

8 8 5

6.5.2 Alignment The alignment of the set should be re-checked at operating temperature (see 5.2.6). Re-align the set, if necessary. 6.6 Special notes Observe the following points during operation: �� Control revolutions and head of the pump. �� Ensure that the pump runs smoothly without

vibrating. �� Control liquid level in the suction or feed tank. �� Control the bearing temperature (maximum

temp. 80°C) �� During the run-in period a slight leakage may

occur. �� Should the temperature of the mechanical seal

rise during run-in shut down pump to allow the seal to cool down.






�� If the pump is equipped with an external flush or quench, the supply line has to be opened before the pump is started up.

�� After shutdown of the pump, allow the mechanical seal to cool down before the shaft seal supply lines or the intensive cooling are closed.

�� In general, a slight leakage of several cm³/h escapes from the mechanical seal as vapour or fog. Besides that, few drops may leak from the mechanical seal as well.

Should the initial leakage rate of the mechanical seal not reduce considerably after a run-in period of approx. 5 minutes, shut down the pump as soon as possible and check the seal. 6.7 Shut-down If there is no no-return valve flap, close the regulation valve in delivery line. Do not switch off driver until then. Close isolating valve in the feed line only if necessary. (Removal of pump) Shut off external sealing. If a vacuum gauge without relief valve is attached to the suction branch of the pump, then it must be isolated before stopping the pump set. If there is danger of the pump freezing up, the pump must be drained. 6.8 Re–starting Before re–starting the set, take care that the pump shaft is at rest and does not rotate backwards. Starting with the shaft rotating in opposite direction may lead to shaft damage.

If e.g. explosive, toxic, hot or crystalline liquids are pumped, you have to make sure that no danger arises to persons or the environment. Even if the pump is completely turned around residues of liquid, remain. If the pump has to be sent back, make sure it is free of any dangerous agents. For a longer standstill, the pump has to be conserved.

CAUTION

Maintenance, dismantling, assembly Page 1 of 5 Chapter 7





7. Maintenance, dismantling, assembly

7.1 General advises

�� Flush the pump thoroughly before disassembly to purge away the residual liquid left after draining the pump.

�� Ensure that people and the environment are not put at risk through explosive, toxic, hot, crystalline, or acid liquids handled.

�� The workplace for disassembly or assembly must be clean.

�� Ensure trouble-free bearing performance, for example by regular inspection of bearing tem-perature or vibration behaviour. The bearing temperature must not exceed 80°C, if oil-lubricated. Bearing operation must be free from vibrations. Heat exchange between the bearing housing and the environment must not be impaired, insulation is not permissible.

�� Inspect the mechanical seal leakage at regular intervals, e.g. by visual inspection. An amount of a few cm³ per hour in the form of vapour, mist or drops is permissible.

�� Assembly and disassembly of this pump must

only be performed by authorised and qualified personnel who have adequately familiarised themselves with the subject matter by studying this manual in detail. Otherwise the pump could be damaged and people and the environment can be put on risk if the pump is operated in a potentially explosive atmosphere.

�� Anti-friction bearings which are old or improperly lubricated may cause the machine temperature to increase and be hazardous to

personnel and environment if the pump is operated in a potentially explosive atmosphere.

�� Leakage from a pump equipped with a single-acting mechanical seal may lead to the forma-tion of explosive mixtures and be hazardous to personnel and environment if the pump is ope-rated in a potentially explosive atmosphere.

�� Only a pump set, which is properly operated and maintained in perfect technical condition, will give safe and reliable operation. This also applies to the reliable function of the rolling element bearings whose actual lifetime largely depends on the operating mode and operating conditions.

�� Regular checks of the lubricant and the running noises will prevent the risk of excessive temperatures as a result of bearings running hot or defective bearing seals.

�� Any auxiliary systems installed must be monitored, if necessary, to make sure they function correctly.

�� Static sealing elements shall be regularly checked for leakage.

�� The coupling guard and any other guards of fast rotating components must be regularly checked for deformation and sufficient distance from rotating elements.

�� Regularly verify the correct position and the status of plastic components exposed to the atmosphere.

�� It is strongly recommended to draw up a maintenance schedule, which includes the above-mentioned points.

7.2 Maintenance and inspection 7.2.1 Oil lubricated bearings The pump is supplied by the manufacturer without oilfilling. Before the first start up, fill in oil into the oil inlet hole until the oil level reaches the mark in the middle of the oil level sight glass.






Oil change intervals New bearings need renewal of the oil after about 200 operating hours and then annually, if the bearing temperature is constantly less then 50°C and there’s no soiling. If the bearing is used at a temperature up to 80°C and/or if the bearing might get soiled it requires a renewal of the oil every six month. Oil Properties ATTENTION: Should the ambient temperatures exceed 80°C or remain under -30°C please consult the manufacturer. Operating

temperature

of bearing

up to 80 °C

Ambient

temperature

< 0°C

n � 1500

rpm

n > 1500

rpm

Type of lubrication

DIN 51517

CL68 CL46 CL22

cinematic viscosity at

50°C in mm²/s

61.2 to

74.8

41.8 to

50.8

19.8 to 24.2

Neutralisation number maximum 0,15 mg KOH/g

Ash (Oxide ash) maximum 0,02% weight

Water content maximum 0,1 % weight

Suitable motor oil SAE 20 and 20 W SAE 10 W

Oil quantities:

Bearing housing size Shaft end-� amount of oil

35 28 0,35 l 45 38 0,6 l 55 48 0,8 l 65 55 0,9 l 75 65 0,97 l 90 80 will follow

The lubricating oil has to be extremely pure and resistant to ageing. It must have good water separating properties and corrosion protection. 7.2.2 Bearings grease lubricated The first filling of the rolling contact bearing and rolling contact bearing spaces in the bearing housing is already effected in the works with the following grease rates per bearing points.

Shaft unit

Grams per bearing

35 45 55 65 75 90

50 75 100 150 200 250

Re-greasing is effected by means of grease gun through the two grease nipples XX. In order to avoid the entry of impurities into the bearings together with the grease, take care that the grease container, greasing device and nipple are clean and that the lubricant does not become contaminated during the transfer procedure. For the individual pump speeds, the different re-greasing intervals have to be observed: Pump speed: r.p.m 1.500 1.800 3.000 Greasing intervals: hours 2.500 2.000 1.500 After approximately 10,000 operating hours, however, after two years at the latest, the rolling contact bearings should be removed, cleaned and replaced with a fresh grease filling (see “Grease properties”). In the case of extremely unfavourable operating conditions (dirty and wet operation, high ambient temperature) the re-greasing must be effected at considerably shorter intervals. During prolonged standstill periods, the

CAUTION






recommendations given by the respective lubricant manufacturers must be observed. Grease rated/grease types When installing the rolling contact bearings with a fresh grease charge, the spaces of the bearings should always be entirely filled with grease, however, then housing space on both sides should only be filled up to one third. If the bearings are overgreased (too much grease in the bearings) there is the danger of their running hot. Use only high-quality lithium soap grease, which is resin- and acid- free and has a rust inhibiting effect. Grease properties: Consistency nº. 2 (Work penetration 265-295) Usable temperature range up to 120ºC Dropping point � 170ºC 7.2.3 Mechanical seal The mechanical seal shows no or little visible leakage. Should the leakage become more intense the mechanical seal has to be checked. Normally the mechanical seal is a single-acting, carbide metal/carbide metal. For it a special casing cover is required which is not identical with the one used for the packed stuffing box. Normally for this mechanical seal, no flushing is required. When flushing is required for particular applications drilled of the flushing liquid connection XXIIIc has to be effected. 7.2.4 Packing The pumps are supplied by us with the packing installed. If, after prolonged operating time, the inserted packing material is worn it must be completely removed, as, other wise, the running surface

sleeve is damaged and this must be replaced too. If no pre-shaped packing rings are available cut packing material to suitable length, e.g. with a gauging plug of the same diameter as the shaft sleeve. A gap of 1 mm between the joints after fitting will, in any case, prove less detrimental than squeezing too long pieces together. Pre-shaped packing must be bent up sidewise and slipped over the shaft sleeve (fig.: 4)

Joint

Correct Incorrect Packing ring: L = mean diameter � �

Fig.: 4 After a certain running-in period, the gland should be tightened evenly until there is only slight leakage from the stuffing box. 7.2.5 Driver Carry out maintenance of the driver, according to the instructions of the manufacturer. 7.3 Disassembly 7.3.1 General If the pump has been maintained and services carefully, breakdowns which necessitate the pump being dismantled should not occur (see section 7 “maintenance”). If, however, faults occur, then before deciding to dismantle the pump the plant should be checked for possible sources of trouble (see section 8 “Breakdown – Cause – Remedy”). If technical personnel are not available, we recommend that you request the service of an erection engineer or prevision of special dismantling instructions or despatch of the pump to our works for checking.






If the pump is being stripped by yourselves, all parts must be handled with greatest care, avoiding blows and shocks. All parts must be carefully cleaned, tested with new parts. After assembly, the rotor must turn easily by hand. Otherwise the bearings, coupling, shaft seal and wear tings opposite the impeller may be damaged prematurely. Inspections of all components, especially of the new ones, to make sure that they do not present sharp edges or burrs and have completely clean surfaces. Make certain that the threads are not damaged. All grease nipples and plugs must be hermetically sealed with a Teflon tape. Prior to erection all flat gaskets should also be provided with grease. Check of the clearance on semi-open impellers On the semi-open impellers the hydraulic efficiency is influenced amongst others by the axial clearance between impeller and wear plate. Check and correct the setting of the axial clearance as show on fig. 5

Clearance 0,5 mm

Gasket

When measuring clamp by means of 2 opposite wooden wedges

fig. 5

Fixing of the rotor towards the suction side of the impeller by inserting 2 wooden wedges set at 180º, measuring of A and B. Required thickness D of the gasket (between casing cover and casing) must be: D = A-B = 0,5 to 1,0 mm

7.3.2 Spare parts The position numbers necessary for ordering spare parts is mentioned in the parts list (see annex). It is important to indicate the serial number that can be found on the type plate of the pump as well. 7.4 Special hints In order to facilitate the fitting of the rolling contact bearings on the shaft, these will be warmed up before on a heating plate. During this procedure the bearings should, however, not be warned up above 100ºC because at temperature of 130ºC they may already be affected. After fitting the bearings on the shaft, they and the grease chambers in the bearing housing have to be filled with grease according to 7.2.2. Once the lubricant, this amount of grease will be enough until the next re-engreasing is due (see 7.2.2). When fitting the bearings in the hosing take care that they will have cooled down; we recommend prior warming up of the housing. When removing the rolling contact bearings from the housing or from the shaft we recommend using a pull-off device or a pressing device because otherwise by driving them out with a hammer the rolling contact bearings may be damaged. 7.5 After dismantling Wash out with detergent all lubricants from the bearings, bearing housing; thereafter dry thoroughly by hand or with clean compressed air. Replace bearings that show signs of material deterioration on their running surfaces. Apply rust inhibiting oil to the bearings and wrap them in paper for protection.






7.6 Assembly 7.6.1 Tightening torques Tightening torque of the screws: Tightening torque of impeller screw 91.41: Nm size of the bearing housing

shaft material 35 45 55 65 75 90

C45N 25 40 98 190 330 330

X6CrNiMoTi 17 12 2 18 30 72 142 245 245

thread M8 M10 M12 M16 M20 M24 M30 M36

tightening

torque

12

Nm

25

Nm

40

Nm

90

Nm

175

Nm

300

Nm

500

Nm

700

Nm

7.7 Inspection After assembly, proceed as follows: �� Check that pump is easy to rotate and leak-

proof �� Check that the axial clearance of the shaft

assembly is within the permissible range (0,15 mm – 0,75 mm)

Troubleshooting Page 1 of 1 Chapter 8






(Sterling Fluid Systems BV 2003)

8. Help in case of trouble

8.1 Use of trained staffTrouble shooting must be undertaken only by appropriately trained personnel.

8.2 Symptoms, causes and remedies

Symptom Cause RemedyDelivery at reduced capacity - Back-pressure to high. Check if the installation is contaminated

with solid particles.Regulate the operation point.

- Pump or pipework no completely filled. Vent and fill the pump and suction or feedline.

- Suction head too high or feed head toolow.

Check the liquid levels, open the isolatingvalves on the suction line, clean thesuction filter or strainer.

- Sealing gap between impeller and wear plate too great.

Exchange the worn out pump parts.

- Wrong direction of rotation. Re-connect electrical supply of the motor.- Pump casing or suction line not tight.

- Impeller clogged.

Exchange casing gasket.Check the flange connections.Dismantle the pump and clean theimpeller.

Pump does not suck at all ordoes not suck properly

- Pump casing, shaft seal, strainer orsuction line not tight.

Exchange casing gasket.Check the shaft seal.Check the flange connections.



- Loose or blocked parts in the pump. Open and clean the pump.

Pump leaks - Casing screws not tight. Check torque moment of the casingscrews.

- Gland packing leaks too much.

- Mechanical seal leaks.

Check the packing rings. In case re-tightthe gland. Otherwise renew the packingrings.

Check the seal surfaces and elastomere ofthe mechanical seal. In case of damagesexchange mechanical seal.

- Gaskets defect. Renew the gaskets.

Temperature increasing in thepump

- Pump or pipework no completely filled. Vent and fill the pump and suction or feedline.



- Gland too tight. Loose gland.

- Pump is working against closed valve. Open the valve on the discharge side.

Pump runs unsteady or noisy - Pump or pipework no completely filled. Vent and fill the pump and suction or feedline.


Check the liquid levels, open the isolatingvalves on the suction line, clean thesuction filter and strainer.

- Pump is not correctly fitted on the baseplate or foundation or pump is understress.

Check the erection of the pump.

- Foreign bodies in the pump. Dismantle and clean the pump.

Disconnecting of motorprotection

- Erection of the pump not plane or pump is under stress.

Check the erection of the pump.

- Pump is running outside the operating conditions.

Observe the operating conditions in thedata sheet.

- Loose or blocked parts in the pump. Open and clean the pump.

Technical data Page 1 of 3 Chapter 9





9. Technical Data For technical information about the pump or pump unit not described in this chapter see data sheet (or delivery note), for the sizes see table of dimensions in the annex. This information is overridden by any information given specifically to your order. Maximum casing pressure up to 120ºC: 10 bar ATTENTION: Note the temperature limits of

operation of the mechanical seal. Branch position: Suction branch axial, discharge branch radially upwards Flanges: The flanges comply with DIN 2501 PN10. Direction of rotation: Clockwise viewed from the motor side towards the pump. Maximum allowed speed, r. p. m:

Pump Impeller Type

Impeller Ø

Bearing type

Maximum rpm

165 03216 03220 F

190 04016 05016 D/F 173

04020 D/F

B/C

05020

06520 Z/F 213/212

3600

D 263 05026 F 260 08026

10026 Z/F 263/260

3000

05032/08032 Z

10032 D 328

05032/08032 10032 F 325

15032 Z

20032 D 328

08040 Z

12540 D/F

20040

408

1800

30040 D

440 960 12550 20050 D 508

S/T

1500

Materials: See chapter 2.4 Vibrations: Vibration level complies with VDI 2056 and ISO 5199 class K for pumps with a driving power of up to 15 kW and class M for driving power of more than 15 kW. Noise emission: The noise emission of the pump meets the directive 001/30 - 1992 of the EUROPUMP Commission. The following table provides approximate values:

noise level, pump without motor

Please consider that additional noise sources may be:

�� driver �� coupling, if misaligned �� Piping (note: the larger the pipe diameters, the

lower the noise emission of the pipes)

k W






Permissible branch forces and moments: Values according to ISO/DIN 5199 – Class II (1997) – Annex B, Family Nº 2 for mounting on sheet metal baseplates and frames without grouting for pumping temperatures up to 110 ºC and up to 120 ºC for grouted baseplates / frames. �� Material execution 0B / 0E:

DN Fy Fz Fx �F My Mz Mx �M flanges (N) (N) (N) (N) (Nm) (Nm) (Nm) (Nm)

32 400 500 440 780 360 420 520 760 40 400 500 440 780 360 420 520 760 50 540 660 600 1040 400 460 560 820 65 820 1000 900 1580 460 520 640 940 80 820 1000 900 1580 460 520 640 940

100 1080 1340 1200 2100 500 580 700 1040 125 1620 2000 1800 3140 700 820 1000 1460 150 1620 2000 1800 3140 700 820 1000 1460 200 2160 2680 2400 4180 920 1060 1300 1920 250 2700 3340 2980 5220 1260 1460 1780 2620

Top

bran

ch z

-Axi

s

300 3220 4000 3580 6260 1720 1980 2420 3560 50 600 540 660 1040 400 460 560 820 65 900 820 1000 1580 460 520 640 940 80 900 820 1000 1580 460 520 640 940

100 1200 1080 1340 2100 500 580 700 1040 125 1800 1620 2000 3140 700 820 1000 1460 150 1800 1620 2000 3140 700 820 1000 1460 200 2400 2160 2680 4180 920 1060 1300 1920 250 2980 2700 3340 5220 1260 1460 1780 2620 300 3580 3220 4000 6260 1720 1980 2420 3560 To

p br

anch

x-A

xis

350 4180 3760 4660 7300 2200 2540 3100 4560

�� Material execution 4B: Multiply by � = 1,536; which is the relationship of E – modules between 1.4408 and GG-25.






Operating range: (Continuous operation)

Size (1/min) Qopt

(m3/h)

Qmin

Factor

Qmax

Factor

1450 350 0,4 1,2 DBSA 12540D

960 230 0,4 1,2

1450 350 0,3 1,3 DBSA 12550D

960 250 0,4 1,2

1450 340 0,3 1,3 DBSA 15032Z

960 220 0,3 1,3

1450 525 0,3 1,3 DBSA 20032D

960 350 0,3 1,3

1450 550 0,3 1,3 DBSA 20040D

960 365 0,3 1,3

1450 600 0,4 1,2 DBSA 20050D

960 450 0,4 1,2

DBSA 30040D 960 935 0,4 1,2

To calculate Qmin and Qmax, the following process will be follow: Qmin = Qmin Factor x Qoptimun Qmax = Qmax Factor x Qoptimun Example: Pump size: DBSA 04016D (1450 1/min) Qmin = 0,3 x 20 = 6 m3/h Qmax = 1,3 x 20 = 26 m3/h This operating range is applicable if waterlike liquids are pumped. If liquids having distinctly dif-ferent physical properties are handled, it may be necessary to narrow the permissible operating range. See the specific permormance curve for more details.

Size (1/min) Qopt (m3/h)

Qmin Factor

Qmax Factor

2900 20 0,3 1,3 DBSA 03216F 1450 10 0,3 1,3

2900 26 0,3 1,3 DBSA 03220F 1450 13 0,3 1,3 2900 40 0,4 1,2 DBSA 04016F 1450 24 0,4 1,2 2900 40 0,3 1,3 DBSA 04016D 1450 20 0,3 1,3 2900 36 0,4 1,2 DBSA 04020F 1450 18 0,4 1,2 2900 31 0,3 1,3 DBSA 04020D 1450 15 0,3 1,3 2900 75 0,4 1,2 DBSA 05016F 1450 40 0,3 1,3 2900 63 0,3 1,3 DBSA 05016D 1450 30 0,4 1,2 2900 75 0,4 1,2 DBSA 05020F 1450 40 0,3 1,3 2900 90 0,4 1,2 DBSA 05020Z 1450 45 0,4 1,2 2900 90 0,4 1,2 DBSA 05026F 1450 45 0,4 1,2 2900 90 0,4 1,2 DBSA 05026D 1450 45 0,4 1,2

DBSA 05032F 1450 90 0,4 1,2 DBSA 05032Z 1450 90 0,4 1,2

2900 110 0,4 1,2 DBSA 06520F 1450 70 0,3 1,3 2900 156 0,4 1,2 DBSA 06520Z 1450 78 0,4 1,2 2900 200 0,4 1,2 DBSA 08026F 1450 118 0,4 1,2 2900 240 0,4 1,2 1450 120 0,4 1,2 DBSA 08026Z 960 80 0,4 1,2

DBSA 08032F 1450 118 0,4 1,2 1450 135 0,4 1,2 DBSA 08032Z 960 90 0,4 1,2

1450 135 0,4 1,2 DBSA 08040Z 960 90 0,4 1,2

2900 270 0,4 1,2 DBSA 10026F 1450 150 0,3 1,3 2900 325 0,3 1,3 1450 162 0,3 1,3 DBSA 10026Z 960 108 0,3 1,3

DBSA 10032F 1450 180 0,4 1,2 1450 195 0,4 1,2 DBSA 10032D 960 130 0,4 1,2

DBSA 12540F 1450 350 0,3 1,3

Annex Page 1 of 10 Chapter 10






© (Sterling Fluid Systems BV) 2003

10. Annex 10.1 Connections

For version with Code Connections

Grease Oil

I Pressure gauge connection

II Pressure/vacuum gauge connection

III Vent

VII Drain

IX Drip and leakage connection

Xa Inlet connection for sealing liquid External sealing

Xb Outlet connection for sealing liquid External sealing

XV Oil filling X

XVI Oil drain X

XVIIa Oil level sight glass X

XVIIb Constant level oiler connection X

XX Grease nipple X

XXIIIa Flushing liquid connexion for shaft seal Flushing before packing

XXIIIb Flushing liquid connexion for wear plate Flushing of wear plate

XXIIIc Seal flushing External sealing








Dimensions of connections

Pumps with shaft unit

35 45 55 65 75 90 Code

Standard

type

Special

type

Standard

type

Special

type

Standard

type

Special

type

Standard

type

Special

type

Standard

type

Special

type

I G 1/2” (4) G 1/2” G 1/2” G 1/2” G 1/2”

II Without

hole G 1/2”

Without

hole G 1/2”

Without

hole G 1/2”

Without

hole G 1/2”

Without

hole G 1/2”

III G 1/2” (5) G 1/2” G3/4” G 1” (3) G 1”

VII G 1/2” (6) G 1/2” (1) G 1” (2) G 1” (3) G 1”

IX G 1/2” G 1/2” G 1/2” G 3/4” G 3/4”

Xa G 1/4” G 1/4” G 1/4” G 3/8” G 3/8”

Xb G 1/4” G 1/4” G 1/4” G 3/8” G 3/8”

XV Ø 20 Ø 20 Ø 20 Ø 20 Ø 20

XVI G 1/4” G 1/4” G 1/4” G 1/4” G 1/4”

XVIIa G 3/4” G 3/4” G 3/4” G 3/4” G 1”

XVIIb G 1/4” G 1/4” G 1/4” G 1/4” G 1/4”

XX M6 M6 M6 M6 M6

XXIIIa G 1/4” G 1/4” G 1/4” G 3/8” G 3/8”

XXIIIb G 1/2” G 1/2” G 1/2” G 1/2” G 1/2”

XXIIIc G 3/8” G 1/2” G 1/2” G 1/2” G 1/2”

On

requ

est

1) G 3/4” in 06520

2) G 3/4” in 05032, 08026 and 08032

3) G 3/4” in 08040

4) G 1/4” in 03216 and 03220

5) Pumps 03216, 03220 not drilled

6) G 1/4” in 03216 and 03220








10.2 Table of Dimensions

Dimensions in mm

Pumps dimensions Foot dimensions Shaft end Spa 1) Size Bearing DN2 DN1 a f h1 h2 b c c1 e1 m1 m2 n1 n2 s s1 w d l t u y o P

03216 425 132 160 15 31503220

35 32 50 80 420 160 180 310

04016 405 180 295- -

04020 35 40 50 90

410 160

200

240 190

30005016 35 100 405 160 295

28 60 31 8

05020 112 180 200

50 6 100 70

265 212

13

05026 45

65 125

500 200 250 8 320 250 15

38 80 41 10

05032 55

50

140 550 225 280 12 345 280 14 48 110 51.5 14 06520 45 65

80 125 500 180 225

65

14

6 125 95

320 250

14

13 38 80 41 10

80 200

08026 130 225 280 08032

55 100 125

550 250 315

12

110

400 315 14

370

48 51.5 14

08040 65 80

670 280 355 15 140 435 355 18 500 55 59 16 10026 225 280 10032

55 100 125 140

550 250 315

80 18

12 110

160 120

400 315

18

14 370 48 51.5 14

140

125 250

12540 65 670 315 400 500 400 55

110

59 16 12550 75

125 720 355 450 550 450 65 140 69 18

15032 150 150 170

280 400 500 400280

20032 65 670

315 450 55 110 59 16

20040 355 500

22 15

550 450

20050 75

200 200 200 720

400 530

100

24 15

140 200 150

600 500

22 18 500

65 140 69 18

180 150

300

30040 Dimensions on request

Dimensions conections flanges according to DIN 2501 PN - 10 DN1/DN2 32 40 50 65 80 100 125 150 200

Ø D 140 150 165 185 200 220 250 285 340 Ø k 100 110 125 145 160 180 210 240 295

d1 x number - - *) 18 x 4

M 16 x 4 *) 18 x 4 M 16 x 4 M 16 x 8 M 16 x 8 M 16 x 8 M 20 x 8 M 20 x 8

d2 x number 18 x 4 18 x 4 18 x 4 18 x 4 18 x 8 18 x 8 18 x 8 22 x 8 22 x 8

*) Only for sizes 32…

1) Piece with flanges (on request)








10.3 Parts list

When ordering spare parts give the following information: position number, the complete pump designation and the serial number, which can be found on the nameplate fixed to the pump. Pos. Nr. Designation 10.20 Volute casing 13.50* Wear plate 16.10 Casing cover 18.30 Foot 21.10* Shaft 23.00* Impeller 26.00* Impeller screw 32.10* Deep groove ball bearing 32.11* Angular contact ball bearing 32.20* Roller bearing 33.00 Bearing housing 36.00 Bearing cover 36.01 Bearing cover 40.00* Flat gasket 40.02* Flat gasket 41.10* Flat gasket 41.11* Flat gasket 41.12* Flat gasket 41.13* Flat gasket 41.14* Flat gasket 41.15* Flat gasket 41.16* Flat gasket 41.17* Flat gasket 41.19* Flat gasket 42.10* Retainer 42.11* Retainer 43.30* Mechanical seal 45.20 Stuffing box gland 45.70* Follower ring 45.80* Lantern ring 46.10* Packing ring

Pos. Nr. Designation 50.50 Washer 50.70* Thrower 52.30* Shaft sleeve 52.40* Shaft sleeve 55.40 Washer 63.60 Conical lubricating nipple 64.20 Oil level sight glass 67.20 Plug 90.10 Hexagonal screw 90.11 Hexagonal screw 90.12 Hexagonal screw 90.13 Hexagonal screw 90.20 Stud 90.21 Stud 90.30 Screw plug 90.31 Screw plug 90.32 Screw plug 90.33 Screw plug 90.34 Screw plug 90.35 Screw plug 90.36 Screw plug 90.37 Screw plug 91.40 Allen screw 91.41 Allen screw 92.00 Hexagonal nut 92.01 Hexagonal nut 92.10 Grooved nut 93.00* Helicoil insert 93.01* Lockwasher 93.02* Washer 93.20* Lockwasher 94.00* Key 94.01* Key *recommended spare parts








Pump with bearing housing type C (Oil lubrication), shaft seal execution BKS/BKW with mechanical seal. For grease lubrication please, see pages 2 and 3

67.20

64.20 90.3741.17

90.3641.16

90.3141.11 40.02

40.02

94.0090.10

42.1050.50 36.0036.01

33.00

21.1042.1191.41

26.0093.00

94.0132.20

90.1150.70

32.10 93.2010.20

90.1293.0218.30

23.00

90.3041.10

90.2092.00

16.10

40.00 43.30

90.3541.15 90.13

52.30

16.1090.3341.13 46.10 45.2045.70

52.40 45.80 55.4090.2192.0145.8052.40

45.70 45.2046.1090.3341.1316.10

55.4090.2192.01

Code 051 Code 052

For explanation of the different executions, please see chapter 2.








Pump with bearing housing type S (Grease lubrication), shaft seal execution BKS/BKW with mechanical seal. For oil lubrication please, see page 1

90.3041.10

93.01

10.2091.4041.1413.50 16.10

90.3241.12 90.13

90.3541.15 42.11

36.0192.10

32.1121.10

36.0063.60 42.10

94.0052.3043.30

40.00 90.2092.00

23.00 50.7090.1194.0193.0026.00

91.4118.30

90.1232.20 33.0090.10

40.0240.02

93.02

90.3141.11

16.1090.3341.13 46.10 45.2045.70

52.40 45.80 55.4090.2192.0145.8052.40

45.70 45.2046.1090.3341.1316.10

55.4090.2192.01

90.2192.0155.40

90.3441.19 16.10

90.3341.13 46.10 45.2045.70

52.40 45.80

Code 051 Code 052 Code 071









Pump with bearing housing type B (Grease lubrication), shaft seal execution BKS/BKW with mechanical seal. For oil lubrication please, see page 1

94.01 94.0090.10

33.0090.1293.02

18.3090.11

50.7043.30

52.30 90.2092.0040.00

93.0091.41 23.00

26.00 90.3041.10

32.2063.60

40.02 40.02 42.1050.5036.0036.01

21.1042.11 32.10 93.2090.35

41.1590.1390.3241.1216.10

90.3141.1113.50

91.4041.1410.20

16.1090.3341.13 46.10 45.2045.70

52.40 45.80 55.4090.2192.0145.8052.40

45.70 45.2046.1090.3341.1316.10

55.4090.2192.01

90.2192.0155.40

90.3441.19 16.10

90.3341.13 46.10 45.2045.70

52.40 45.80

Code 051 Code 052 Code 071









Max. permissible temperature of pumping liquid The highest temperatures usually occur on the pump casing surface, on the bearing housing in the area of the anti-friction bearings and on the casing cover near the mechanical seal. The temperature occurring on the pump casing is almost the same as that of the liquid handled. A maximum temperature of 80 °C, if oil-lubricated, can be expected in the area of the anti-friction bearings, provided the requirements for appropriate pump operation are met and regular maintenance on the bearings is provided. Insulation of the bearing housing is not permissible. If the pump is adequately filled with liquid, the temperature of the liquid handled in the shaft seal area should not increase by more than 20 °K for dead end operation with a single-acting mechanical seal. With double-acting mechanical seals the temperature rise depends largely on the flushing or sealing liquid (if there is any doubt, please contact Sterling Fluid Systems). Thus, the following theoretical maximum temperature of the liquid handled as a function of the temperature class according to EN 13463-1 is obtained. The maximum operating temperature of the pump (see chapter 9) and the operating limits of the mechanical seal must be observed (if there is any doubt, please contact Sterling Fluid Systems or the mechanical seal manufacturer).

Temperature classes Permissible Max. permissible fluid as per EN 13463-1: surface temperature for compliance temperature with temperature class

T5 100 º C 80 º C T4 135 º C 115 º C T3 200 º C Temperature limit of pump T2 300 º C Temperature limit of pump T1 450 º C Temperature limit of pump

Make sure that the pump is always started up with the suction-side shut-off valve fully open and the discharge-side shut-off valve slightly open. However, the pump can also be started up against a closed swing check valve. Only after the pump has reached full rotational speed shall the discharge-side shut-off valve be adjusted to comply with the duty point. Safety note:








The permissible operating temperature of the pump in question is indicated in the technical data. If the pump is to be operated at a higher temperature, the technical data are missing or if the pump is part of a pool of pumps, the maximum permissible operating temperature must be requested from the pump manufacturer.

Pump operation with closed shut-off valves in the suction and / or discharge pipes is not permitted. In this case, there is a risk of the pump casing reaching a high surface temperatures after a very short time, due to a rapid temperature rise in the pumped fluid inside the pump. Additionally, the resulting rapid pressure build-up inside the pump may cause excessive stresses on the pump materials and even cause it to burst. The minimum flows indicated in the pump operating manual refer to water and water-like liquids. Longer operating periods with these liquids and at the flow rates indicated will not cause an additional increase in the temperatures on the pump surface. However, if the physical properties of the fluids handled are different from water, it is essential to check if an additional heat build-up may occur and if the minimum flow rate must therefore be increased. The calculation formula below can be used to check if an additional heat build-up may lead to a dangerous temperature increase at the pump surface.

To = Tf + ��

�� = ((g * H) / (c * �))*(1 - �)

c Specific heat of liquid [J / kg K] g Acceleration due to gravity [m2/s] H Pump head [m] Tf Temperature of fluid handled [º C] To Temperature of casing surface [º C] � Pump efficiency [-] �� Temperature difference [º C]








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Sterling Fluid Systems (Spain), S.A.Vereda de los Zapateros, s/n28223 Pozuelo de Alarcon (Madrid) EspañaPhone: 0034 91 7091310, Fax: 0034 91 7159700

Declaration of ConformityIn the sense of the EU Directive 98/37/EC, Appendix II B

Herewith we declare that the pump type:

In the version supplied by us complies with the following relevant regulations:

EU Machine Directive 98/37/EC, Appendix I No. 1EU Directive 94/9/EC, Group II, category 2, atmosphere G (Ex II 2 G c T1-T5)

And that is destined for installation in a machine / assembly with other machines to form asingle machine and that it may not be commissioned until it has been determined that themachine in which this pump is to be installed or with which this pump is to be assembledcomplies with the clauses of the EU Machine Directive in the version of 98/37/EC and94/9/EC.

Harmonised standards used, in particular:

EN 809 ISO 2558 Dimensions EN 1127 - 1EN 292 part 1 EN 13463 - 1EN 292 part 2 prEN 13463 - 5In the actual version.

National technical standards and specifications used, in particular:

UNE-EN 809 UNE-EN 1127-1UNE-EN 292-1 UNE-EN 13463 - 1UNE-EN 292-2

Unauthorised alterations of the pump unit and any use not in accordance with validregulations and / or intended use result in a loss of validity of this declaration.

Sterling Fluid Systems, (Spain), S.A.

Business Unit Manager

J. A. CoboJune 10, 2003

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