Dahlen ICP, ICPI, ICPH, ICPIH Installation Manual

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Page 1

GOULDS PUMPS

Installation, Operation

and

Maintenance Instruction

Volute Casing Pumps

Model:

ICP

ICPI

ICPH

ICPIH

Page 2

IMPORTANT SAFETY NOTICE

To: Our Valued Customers

User safety is a major focus in the design of our products. Following the precautions outlined in this manual will minimize your risk of injury.

ITT Goulds pumps will provide safe, trouble-free service when properly installed, maintained, and operated.

Safe installation, operation, and maintenance of ITT Goulds Pumps equipment are an essential end user responsibility. This Pump Safety Manual identifies specific safety risks that must be considered at all times during product life. Understanding and adhering to these safety warnings is mandatory to ensure personnel, property, and/or the environment will not be harmed. Adherence to these warnings alone, however, is not sufficient — it is anticipated that the end user will also comply with industry and corporate safety standards. Identifying and eliminating unsafe installation, operating and maintenance practices is the responsibility of all individuals involved in the installation, operation, and maintenance of industrial equipment.

Please take the time to review and understand the safe installation, operation, and maintenance guidelines outlined in this Pump Safety Manual and the Instruction, Operation, and Maintenance (IOM) manual. Current manuals are available at your nearest Goulds Pumps sales representative.

www.gouldspumps.com/literature_ioms.html or by contacting

These manuals must be read and understood before installation and star t-up.

For additional information, contact your nearest Goulds Pumps sales representative or visit our Web site at

www.gouldspumps.com.

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SAFETY WARNINGS

Specific to pumping equipment, significant risks bear reinforcement above and beyond normal safety precautions.

WARNING

A pump is a pressure vessel with rotating parts that can be hazard o us. An y press ure vessel can explode, rupture, or discharge its contents if sufficiently ove r press u r i zed causi n g deat h, personal injury, property damage, and/or damage to the environment. All necessary measures must be taken to ensure over pressurization does not occur.

WARNING

Operation of any pumping system with a blocked suction and discharge must be avoided in all cases. Operation, even for a brief period under these conditions, can cause superheating of enclosed pumpage and result in a violent explosion. All necessary measures must be taken by the end user to ensure this condition is avoided.

WARNING

The pump may handle hazardous and/or toxic fluids. Care must be taken to identify the contents of the pump and eliminate the possibility of exposure, particularly if hazardous and/or toxic. Potential hazards include, but are not limited to, high temperature, flammable, acidic, caustic, explosive, and other risks.

WARNING

Pumping equipment Instruction, Operation, and Maintenance manuals clearly identify accepted methods for disassembling pumping units. These methods must be adhered to. Specifically, applying heat to impellers and/or impeller retaining devices to aid in their removal is strictly forbidden. Trapped liquid can rapidly expand and result in a violent explosion and injury.

ITT Goulds Pumps will not accept responsibility for physical injury, damage, or delays caused by a failure to observe the instructions for installation, operation, and maintenance contained in this Pump Safety Manual or the current IOM available at www.gouldspumps.com/literature.

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SAFETY

DEFINITIONS

Throughout this manual the words WARNING, CAUTION, ELECTRICAL, and ATEX are used to indicate where special operator attention is required.

Observe all Cautions and Warnings highlighted in this Pump Safety Manual and the IOM provided with your equipment.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Example:

Pump shall never be operated without coupling guard installed correctly.

CAUTION

Indicates a hazardous situation which, if not avoi ded, could result in minor or moderate injury.

Example: Throttling flow from the suction side may cause cavitation and pump damage.

ELECTRICAL HAZARD



Indicates the possibility of electrical risks if directions are not followed.

Example: Lock out driver power to prevent electric shock, accidental start-up, and physical injury.

 When installed in potentially explosive atmospheres, the instructions that follow the Ex symbol must be

followed. Personal injury and/or equipment damage may occur if these instructions are not followed. If there is any question regarding these requirements or if the equipment is to be modified, please contact an ITT Goulds Pumps representative before proceeding.

Example: parts, resulting in a spark and heat generation.

 Improper impeller adjustment could cause contact between the rotating and stationary

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GENERAL PRECAUTIONS

WARNING

A pump is a pressure vessel with rotating parts that can be hazardous. Hazardous fluids may be contained by the pump including high temperature, flammable, acidic, caustic, explosive, and other risks. Operators and maintenance personnel must realize this and follow safety measures. Personal injuries will result if procedures outlined in this manual are not followed. ITT Goulds Pumps will not accept responsibility for physical injury, damage or delays caused by a failure to observe the instructions in this manual and the IOM provided with your equipment.

WARNING

General Precautions

NEVER use heat to disassemble pump due to risk of explosion from tapped liquid.

NEVER APPLY HEAT TO REMOVE IMPELLER. It may explode due to trapped liquid.

WARNING

WARNING WARNING

WARNING





NEVER operate pump without safety devices installed.

 



NEVER operate pump without coupling guard correctly installed. NEVER run pump below recommended minimum flow when dry, or without

prime. ALWAYS lock out power to the driver befo re per fo rming pump maintenance.

NEVER operate pump with discharge valve closed. NEVER operate pump with suction valve closed.

DO NOT change service application without approval of an authorized ITT Goulds Pumps representative.

Safety Apparel:

 Insulated work gloves when handling hot bearings or using bearing heater  Heavy work gloves when handling parts with shar p ed ges, especially

impellers

 Safety glasses (with side shields) for eye protection  Steel-toed shoes for foot protection when handling parts, heavy tools, etc.  Other personal protective equipment to protect against hazardous/toxic fluids

Receiving:

Assembled pumping units and their components are heavy. Failure to properly lift and support equipment can result in serious physical injury and/or equipment damage. Lift equipment only at specifically identified lifting points or as instructed in the current IOM. Current manuals are available at

www.gouldspumps.com/literature_ioms.html or from your local ITT Goulds

Pumps sales representative. Note: Lifting devices (eyebolts, slings, spreaders, etc.) must be rated, selected, and used for the entire load being lifted.

Alignment:

WARNING

Shaft alignment procedures must be followed to prevent catastrophic failure of



drive components or unintended contact of rotating parts. Follow coupling manufacturer’s coupling installation and operation procedures.

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WARNING

CAUTION

General Precautions

Before beginning any alignment procedure, make sure driver power is locked out.



Failure to lock out driver power will result in serious physical injury.

Piping:

Never draw piping into place by forcing at the flan ged con necti on s of t he pump. This may impose dangerous strains on the unit and cause misalignment between



pump and driver. Pipe strain will adversely effect the operation of the pump resulting in physical injury and damage to the equipment.

WARNING

CAUTION

WARNING

Flanged Connections:

Use only fasteners of the proper size and material. Replace all corroded fasteners.

Ensure all fasteners are properly tightened and there are no missing fasteners.

Startup and Operation:

When installing in a potentially explosive environment, please ensure that the



motor is properly certified. Operating pump in reverse rotation may result in contact of metal parts, heat



generation, and breach of containment. Lock out driver power to prevent accidental start-up and physical injury.



The impeller clearance setting procedure must be followed. Improperly setting the clearance or not following any of the proper procedures can result in sparks,



unexpected heat generation and equipment damage. If using a cartridge mechanical seal, the centering clips must be installed and set

screws loosened prior to setting impeller clearance. Failure to do so could result



in sparks, heat generation, and mechanical seal damage. The coupling used in an ATEX classified environment must be properly certified



and must be constructed from a non-sparking material. Never operate a pump without coupling guard properly installed. Personal injury

will occur if pump is run without coupling guard. Make sure to properly lubricate the bearings. Failure to do so may result in excess



heat generation, sparks, and / or premature failure. The mechanical seal used in an ATEX classified environment must be properly

certified. Prior to start up, ensure all points of potential leakage of process fluid to



the work environment are closed. Never operate the pump without liquid supplied to mechanical seal. Running a

mechanical seal dry, even for a few seconds, can cause seal damage and must be



avoided. Physical injury can occur if mechanical seal fails. Never attempt to replace packing until the driver is properly locked out and the

coupling spacer is removed.

WARNING

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Dynamic seals are not allowed in an ATEX classified environment.



DO NOT operate pump below minimum rated flows or with suction and/or discharge valve closed. These conditions may create an explosive hazard due to



vaporization of pumpage and can quickly lead to pump failure and physical injury.

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WARNING

CAUTION

WARNING

CAUTION



General Precautions

Ensure pump is isolated from system and pressure is relieved before disassembling pump, removing plu gs, ope ni n g vent or drain valves, or disconnecting piping.

Shutdown, Disassembly, and Reassembly:

Pump components can be heavy. Proper methods of lifting must be employed to avoid physical injury and/or equipment damage. Steel toed shoes must be worn at all times.

The pump may handle hazardous and/or toxic fluids. Observe proper decontamination procedures. Proper personal protective equipment should be worn. Precautions must be taken to prevent physical injury. Pumpage must be handled and disposed of in conformance with applicable environmental regulations.

Operator must be aware of pumpage and safety precautions to prevent physical injury.

Lock out driver power to prevent accidental startup and physical injury. Allow all system and pump components to cool before handling them to prevent

physical injury. If pump is a Model NM3171, NM3196, 3198, 3298, V3298, SP3298, 4150, 4550,

or 3107, there may be a risk of static electric discharge from plastic parts that are not properly grounded. If pumped fluid is non-conductive, pump should be drained and flushed with a conductive fluid under conditions that will not allow for a spark to be released to the atmosphere.

Never apply heat to remove an impeller. The use of heat may cause an explosion due to trapped fluid, resulting in severe physical injury and property damage.

Wear heavy work gloves when handling impellers as sharp edges may cause physical injury.

Wear insulated gloves when using a bearing heater. Bearings will get hot and can cause physical injury.

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ATEX CONSIDERATIONS and INTENDED USE

Special care must be taken in potentially explosive environments to ensure that the equipment is properly maintained. This includes but is not limited to:

1. Monitoring the pump frame and liquid end temperature.

2. Maintaining proper bearing lubrication.

3. Ensuring that the pump is operated in the intended hydraulic range.

The ATEX conformance is only applicable when the pump unit is operated within its intended use. Operating, installing or maintaining the pump unit in any way that is not covered in the Instruction, Operation, and Maintenance manual (IOM) can cause serious personal injury or damage to the equipment. This includes any modification to the equipment or use of parts not provided by ITT Goulds Pumps. If there is any question regarding the intended use of the equipment, please contact an ITT Goulds represe ntative before proceeding. Current IOMs are available at Pumps Sales representative.

All pumping unit (pump, seal, coupling, motor and pump accessories) certified for use in an ATEX classified environment, are identified by an ATEX tag secured to the pump or the baseplate on which it is mounted. A typical tag would look like this:

www.gouldspumps.com/literature_ioms.html or from your local ITT Goulds

The CE and the Ex designate the ATEX compliance. The code directly below these symbols reads as follows:

II = Group 2 2 = Category 2 G/D = Gas and Dust present T4 = Temperature class, can be T1 to T6 (see Table 1)

Table 1

Max permissible

surface temperature

Code

T1 842 (450) 700 (372) T2 572 (300) 530 (277) T3 392 (200) 350 (177) T4 275 (135) 235 (113) T5 212 (100) Option not available T6 185 (85) Option not available

F (oC)

The code classification marked on the equipment must be in accordance with the specified area where the equipment will be installed. If it is not, do not operate the equipment and contact your ITT Goulds Pumps sales representative before proceeding.

Max permissible

liquid temperature

F (oC)

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Page 9

PARTS

The use of genuine Goulds parts will provide the safest and most reliable operation of your pump. ITT Goulds Pumps ISO certification and quality control procedures ensure the parts are manufactured to the highest quality and safety levels.

Please contact your local Goulds representative for details on genuine Goulds parts.

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Installation, Operating and Maintenance Instruction

TABLE of CONTENTS

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

ATEX-Label (only for pumps in compliance with

EC directive 94/9/EC)................................................ 2

1. General ..................................................................3

1.1 Guarantee.........................................................3

2. Safety Regulations ............................................... 3

2.1 Marking of References in the Operating

Instructions..............................................................3

2.2 Dangers of non-observance of the Safety

Instructions..............................................................4

2.3 Safety Instructions for the Operator / Worker...4

2.4 Safety Instructions for Maintenance, Inspections

and Mounting Work.................................................4

2.5 Unauthorized Alteration and Spare Parts

Production............................................................... 4

2.6 Undue Operation............................................... 4

2.7 Explosion Protection......................................... 4

2.8 Use acc. to Regulations.................................... 6

3. Description............................................................ 6

3.1 Design............................................................... 6

3.2 Shaft Sealing..................................................... 6

3.3 Bearings............................................................ 7

3.4 Approximate Value for Sound Pressure Level.. 7

3.5 Permitted Nozzle Loads and Torques at the

Pump Nozzles ........................................................ 7

4. Transport, Handling, Storage.............................. 8

4.1 Transport, Handling ..........................................8

4.2 Storage / Conservation.....................................9

5. Mounting / Installation ......................................... 9

5.1 Mounting of Pump / Unit ...................................9

5.2 Connection of Pipings to the Pump ................10

5.3 Coupling.......................................................... 10

ICP 100-English page 1

Article No 24264412

5.4 Drive................................................................12

5.5 Electric Connection .........................................12

5.6 Final Control....................................................12

6. Start-up, Operation, Shut down.........................12

6.1 Initial start-up...................................................12

6.2 Switch on drive................................................12

6.3 Restarting........................................................13

6.4 Limits of Operation ..........................................13

6.5 Lubrication of Bearings....................................13

6.6 Monitoring........................................................14

6.7 Shutting down..................................................14

6.8 Storage / longer periods of non-operation.......14

7. Servicing, Maintenance......................................15

7.1 General remarks..............................................15

7.2 Mechanical seals.............................................15

7.3 Stuffing boxes..................................................15

7.4 Lubrication and Change of Lubricant..............15

7.5 Coupling ..........................................................15

7.6 Cleaning of pump ............................................16

8. Dismantling and repair of pump........................16

8.1 General remarks..............................................16

8.2 General............................................................16

8.3 Disassembly of Back Pull Out Assembly ........16

8.4 Removal of Impeller ........................................17

8.5 Removal of Shaft Sealing................................17

8.6 Removal of Bearing.........................................17

8.7 Reconditioning.................................................18

8.8 Mounting..........................................................18

9. Recommended Spare Parts, Spare Pumps......19

9.1 Spare Parts......................................................19

9.2 Stand-by pumps ..............................................20

10. Faults - Causes and Solutions.........................20

Model ICP

Revision 00

Issue 05/2006

Page 11

Installation, Operating and Maintenance Instruction

Pump Name Plate

Model ICP

TYPE *) Type and size of pump S/N *) Serial number YEAR Year of construction Q Rated capacity at the operating point P Rated power at the operating point H Head (Energy head) at the operating point N Speed P

Max. permitted casing-operation-pressure

all w C

(=highest discharge pressure at the rated operating temperature to which the pump casing can be used).

TEMP Rated operating temperature of pumped

liquid

ITEM NO Customer equipment number

*) All details of design and materials are defined with this information. They must be stated on all inquiries to the manufacturer resp. orders of spare.

MATL Material of construction

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

CE Marking of compliance with the EC directive

94/9/EC Ex specific marking for explosion protection II Symbol for the appliance group 2G 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 chapter

2.7.5; Data for maximum permitted tempera-

ture of pumped liquid refer to pump name

plate, data sheet and / or order confirmation.

ICP 100-English page 2

Article No 24264412

The conformity with the EC directive 94/9/EC " Equipment and Protective Systems for Use in Potentially Explosive Atmospheres " is declared by the issue of the EC-Declaration of Conformity and the attachment of the ATEX-label at the pump (bearing bracket). The ATEX-label is attached additionally to the pump name plate.

Revision 00

Issue 05/2006

Page 12

Installation, Operating and Maintenance Instruction

1. General

Model ICP

This product corresponds with the requirements of the Machine directive 98/37/EG (former 89/392/EWG).

The staff employed on installation, operation, inspection and maintenance must be able to prove that they know about the relevant accident prevention regulations and that they are suitably qualified for this work. If the staff does not have the relevant knowledge, they should be provided with suitable instruction.

The operation safety of the delivered pump resp. unit (= pump with motor) can only be guaranteed on designated use according to the attached data sheet and / or order confirmation resp. chapter 6 "Start-up, Operation, Shut down". The operator is responsible for following the instructions and complying with the safety requirements given in these Operating Instructions. Smooth operation of the pump or pump unit can only be achieved if installation and maintenance are carried out carefully in accordance with the rules generally applied in the field of engineering and electrical engineering. If not all the information can be found in these Operating Instructions, please contact us. The manufacturer takes no responsibility for the pump or pump unit if the Operating Instructions are not followed. These Operating Instructions should be kept in a safe place for future use. If this pump or pump unit is handed on to any third party, it is essential that these Operating Instructions and the operating conditions and working limits given in the Confirmation of Order are also passed on in full.

These Operating Instructions do not take into account all design details and variants nor all the possible chance occurrences and events which might happen during installation, operation and maintenance. We retain all copyright in these Operating Instructions; they are intended only for personal use by the owner of the pump or the pump unit. The Operating Instructions contain technical instructions and drawings which may not, as a whole or in part, be reproduced, distributed or used in any unauthorised way for competitive purposes or passed on to others.

1.1 Guarantee

The guarantee is given in accordance with our Conditions of Delivery and/or the confirmation of order. Repair work during the guarantee period may only be carried out by us, or subject to our written approval. Otherwise the guarantee ceases to apply. Longer-term guarantees basically only cover correct handling and use of the specified material. The guarantee shall not cover natural wear and tear and all parts subject to wear, such as impellers, shaft sealings, shafts, shaft sleeves, bearings, wear rings etc. or damage caused by transport or improper handling. In order for the guarantee to apply, it is essential that the pump or pump unit is used in accordance with the operating conditions given on the name plate, confirmation of order and in the data sheet. This applies particularly for the endurance of the materials and smooth running of the pump and shaft sealing. If one or more aspects of the actual operating conditions are different, we should be asked to confirm in writing that the pump is suitable.

2. Safety Regulations

These Operating Instructions contain important instructions which must be followed when the pump is assembled and commissioned and during operating and maintenance. For this reason, these Operating Instructions must be read by the skilled staff responsible and/or by the operator of the plant before it is installed and commissioned, and they must be left permanently available at the place where the pump or pump unit is in use.

These Operating Instructions do not refer to the General Regulations on Accident Prevention or local safety and/or operating regulations. The operator is responsible for complying with these (if necessary by calling in additional installation staff).

Equally, instructions and safety devices regarding handling and disposal of the pumped media and/or auxilliary media for flushing, lubrication a.s.o., especially if they are explosive, toxical, hot a.s.o., are not part of this operating instruction.

ICP 100-English page 3

Article No 24264412

For the competent and prescribed handling only the operator is responsible.

2.1 Marking of References in the Operating Instructions

The safety regulations contained in these Operating Instructions are specially marked with safety signs acc. to nach DIN 4844:

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

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

General Symbol for Danger! Persons can be endangered.

Warning of electric voltage!

Revision 00

Issue 05/2006

Page 13

Installation, Operating and Maintenance Instruction

Safety instructions attached directly to the pump resp. unit must be followed under any circumstances. Further they must be kept in good readable condition.

In the same way, as these Operating Instructions of the pump, all possibly attached Operating Instructions of accessories (e.g. motor) must be noticed and kept available.

2.2 Dangers of non-observance of the Safety Instructions

Non-observance of the Safety Instructions can lead 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 endangered to explosion special attention must be paid to sections 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 of the pump/pump unit, and its specified characteristics. The operator must ensure that regular inspection and maintenance are carried out so that all parts are replaced in good time, which would otherwise endanger the safe operation of the system. If abnormal operation or any damage are observed, the pump must cease operation immediately.

 If the breakdown or failure of any system or unit

could lead to people being hurt or property being damaged, such system or unit must be provided with alarm devices and/or spare modules, and they should be tested regularly to ensure that they function properly.

 If there is any risk of injury from hot or cold ma-

chine parts, these parts must be protected against contact by the user, or suitable warning signs must be affixed.

 Contact protection on moving parts (e.g. coupling

guards) must not be removed from systems that are in operation.

 If the sound level of a pump or pump unit is above

85 dB(A) an ear protection has to be used when staying near the pump for some time.

 If dangerous media (e.g. explosive, toxic, hot)

leak out (e.g. from shaft seals), these must be directed away so that there is no danger to people or the environment. The provisions of the law must be observed.

ICP 100-English page 4

Article No 24264412

 Measures should be taken to exclude any danger

from electricity (e.g. by complying with the local regulations on electrical equipment). If work is carried out on live electrical components, they should be unplugged from the mains or the main switch turned off and fuse unscrewed. A motor protection switch is to be provided.

Model ICP

2.4 Safety Instructions for Maintenance, Inspections and Mounting Work

 The operator is responsible that any maintenance,

inspections and mounting work is made by authorized competent personnel, which must be informed by havingng read the Operating Instructions.

 Basically, all work on the pump or pump unit

should only be carried out when the pump is stationary and not under pressure. All parts must be allowed to return to ambient temperature. Make sure that no-one can start the motor during such work. It is essential that the procedure for stopping the system described in the Operating Instructions is observed. Pumps or pump systems that carry media that are dangerous to health must be decontaminated before being taken apart. Safety Data Sheets for the various liquids handled. Immediately after finishing work, all safety and protective devices must be replaced or restarted.

2.5 Unauthorized Alteration and Spare Parts Production

Alteration or changes of the machine are permitted after agreement with the manufacturer. Original spare parts and accessory authorized by the manufacturer are serving the safety. The use of other parts can lead to loss of liability for therefrom resulting consequences.

2.6 Undue Operation

The operating safety of the delivered machine can only be guaranteed by designated use acc. to the following chapters of the Operating Instructions. The limits stated in the data sheet and / or order confirmation must not be exceeded under any circumstances.

2.7 Explosion Protection

On application of units in areas endangered to explosion measures and references in the chapters 2.7.1 to

2.7.6 must be observed, so that explosion protection is guaranteed.

2.7.1 Filling of unit

During operation of the pump the system of the suction and pressure pipe and the pump itsel must permanently be filled with the pumped liquid. Thus, no explosive atmosphere can develop and the danger of dry-run is avoided.

Revision 00

Issue 05/2006

Page 14

Installation, Operating and Maintenance Instruction

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

Equally all seal casings, auxiliary systems o the shaft sealing, as well as heating and cooling systems must be filled carefully.

2.7.2 Marking

The marking of the pump refers to the pump itself. For coupling and motor resp. further additions a separate Declaration of Conformity, as well as a corresponding marking must be available.

Example of of marking at pump:

CE Ex II 2 G c T... .

The marking shows the theoretically applicable range of temperature classes. The different temperatures, permitted acc. to pump design, result as shown in chapter 2.7.5. The same is valid for the drive. For a whole unit (pump, coupling, motor) with different temperature classes the lowest is valid.

2.7.3 Rotation Control

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

If danger of explosion is also existing during installation, the rotation control must not be carried out by short start-up of the empty pump, to avoid undue temperature increase in case o contact of rotating and stationary parts.

2.7.4 Operation of pump

The pump must only be started up with fully opened suction side and slightly opened pressure side valve. The start-up against closed non-return valve, however, is possible. Immediately after the start-up the discharge side valve must be adjusted to the operating point. Refer to chapter 6.2, as well.

Operation with closed valve in suction and / or discharge pipe is not permitted!

There´s a danger, that high surface temperatures are developing at the pump casing afte relatively short time, through fast heating of the liquid inside the pump.

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

In chapter 6.4.1 the minimum flow is stated. Longer operating phases with these flows and the named liquids don´t cause additional increase of surface temperature at the pump. Furthermore the references in chapter 6 of these operating Instructions must be taken into consideration.

ICP 100-English page 5

Article No 24264412

Model ICP

On pumps with mech. seals the permitted temperature limits can be exceeded due to dry-run. Dry run not only can occur on insufficiently filled seal casing, but also because of too much gas in the medium. Operation of the pump out of the permitted operating range can lead to dry-run, as well.

2.7.5 Temperature Limits

Under normal operating conditions the highest temperatures must be expected at the surface of the pump casing and in the area of the bearings.

The surface temperature occurring at pump casing corresponds with the temperature of the pumped liquid.

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

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

During operation of the pump it must be secured that an overabundant sedimentation o dust is avoided (regular cleaning), to prevent heating of pump surface over the permitted temperature.

The operator of the plant must secure that the defined operating temperature is observed. The max. allowed temperature of the pumped liquid at suction depends on the particular temperature class.

The following table shows the theoretical temperature limits of the pumped liquid in consideration of the temperature classes acc. to EN 13463-1.

Temperature class acc.

EN 13463-1

Temperature limit of

pumped 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 of the pump is shown in the data sheet and / o the order confirmation resp. the type plate at the pump.

In the area of the bearings the temperature class T4 is guaranteed, provided that the ambient temperature is 40°C and the appliance is duly operated and maintained.

2.7.6 Maintenance

For a secure and reliable operation it must be secured by regular inspections, that the unit is maintained competently and is kept in good technical condition.

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Issue 05/2006

Page 15

Installation, Operating and Maintenance Instruction

Example: Function of bearings. Operation and application conditions are essentially responsible for their achievable life cycle.

By regular control of the lubricant and the running sound the danger of occurring over temperatures by bearings running hot or defect bearing seals is avoided. Refer to chapter 6.6 and 7.4. The function of the shaft sealing must be secured by regular control. If auxiliary systems (e.g. external flushing, cooling, heating) are installiert, it must be checked, if monitoring devices are necessary to secure the function.

2.7.7 Electric switches and control device, Instrumentation and accessories

Electric switches and control devices, instrumentation and accessories like e.g. flush tanks, a.s.o., must correspond with the valid safety requirements and regulations for explosion protection.

2.8 Use acc. to Regulations

2.8.1 Speed, Pressure, Temperature

Suitable safety measures must be taken at the plant to ensure that the speed, pressure and temperature of the pump and the shaft sealing do not exceed the limit values given in the data sheet and / or order confirmation. The given admission pressures (system pressures) must also be sufficiently high.

Further, pressure shocks, as can occur on too fast shut down of the facility, must be kept away from the pump (e.g. by non-return valve at pressure side, fly wheel, airtanks). Quick temperature changes must be avoided. They could cause a temperature shock and lead to damage or impair the function of single components.

2.8.2 Permitted Nozzle Loads and Torques

Model ICP

Basically the suction and discharge piping must be designed in such way, that as little forces as possible are effective to the pump. If that is not possible, the values shown in chapter 3.5 must not be exceeded under any circumstances. This is valid for the operation as well as for the standstill of the pump and therefore for all possible pressures and temperatures of the unit.

2.8.3 NPSH

The pumped liquid must have a min. pressure NPSH at the impeller inlet, so that cavitation free work is secured resp. a "break off" of the pump flow is prevented. This condition is fulfilled, 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 NPSHvalue on pumping liquids near the vapour pressure. If the NPSH-value of the pump remains under, this can lead from damage of the material due to cavitation to destruction by overheating. The NPSH-value of the pump (NPSHR) is shown in the curves of every pump type.

2.8.4 Sealing, Flushing, Cooling

Suitable provisions for the regulation and monitoring of sealing, flushing or cooling are to be provided. When handling dangerous liquids or if temperatures are high, care should be taken to ensure that the pump ceases operating if the sealing, flushing or cooling system fails. Sealing, flushing and cooling systems must always be operational before the pump is started up. They should not be taken out of operation until the pump has stopped, provided that the nature of the operation allows this at all.

2.8.5 Back Flow

In systems where pumps are operating in closed circuits under pressure (gas cushions, steam pressure), the pressure of the gas cushion must not be reduced via the pump, since the back flow speed may be much higher than the operating speed, which would destroy the unit.

3. Description

3.1 Design

ICP-pumps are single-stage volute casing pumps in

process design. Hydraulic design and dimensions comply with ISO 2858/ EN 22858, the technical design complies with ISO 5199/EN 25199. For pump pressure up to 25 bar and volute casing with centerline feet. ICPI-pumps as design ICP, except that they have an inducer. ICPH- and ICPIH-pumps pumps additionally possess a cooling or heating of the casing cover and/or the volute casing.

ICP 100-English page 6

Article No 24264412

The pumps are designed as modular systems and can, therefore, be delivered in many variants (e.g. different materials, shaft sealings, different kinds of lubrication, cooling / heating, a.s.o.). The permitted application conditions and design details of the delivered pump are shown in the attached data sheet and / or order confirmation.

3.2 Shaft Sealing

Basically there are two kinds of shaft sealing: the paccking and the mechanical seal, whereas, there again are many variants of both kinds. At the data

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sheet and / or the order confirmation the shaft sealing type of your pump is shown. An instruction for the packing of a stuffing box resp. for the mounting and operation of mech. seals can be found in the appendix of the particular "Mounting Instructions of the Shaft Sealing".

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

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

3.3 Bearings

The pump shaft is guided by antifriction bearings. In the data sheet and / or order confirmation you can see, if your pump is designed for oil lubrication (standard design) or grease lubrication (special design).

In areas endangered to explosion the use o pumps with grease lubricated bearings is forbidden!

3.3.1 Used bearings

The size of the bearing bracket of your pump is shown in the data sheet and / or order confirmation.

Bearing bracket

24 6307 - C3 3307A - C3 32 6309 - C3 3309A - C3 42 6311 - C3 3311A - C3 48 6313 - C3 3313A - C3

pump side drive side

Bearing type

3.3.2 Oil Sump Cooling

On temperatures of the pumped liquid over 160°C an oil 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 Pressure Level

Nominal power PN in kW

0,55 50,5 49,5 49,0 58,0 52,0 51,5 0,75 52,0 51,0 50,5 59,0 54,0 53,0

1,1 54,0 53,0 52,5 60,0 55,5 54,5 1,5 55,5 55,0 54,5 63,5 57,0 56,0 2,2 58,0 57,0 56,5 64,5 59,0 58,5 3,0 59,5 58,5 58,0 68,5 61,0 62,0 4,0 61,0 60,0 59,5 69,0 63,0 63,0 5,5 63,0 62,0 61,5 70,0 65,0 65,0

7,5 64,5 63,5 63,0 70,5 67,0 67,0 11,0 66,5 65,5 65,0 72,0 69,0 68,5 15,0 68,0 67,0 66,5 72,5 70,0 70,5

2950

min-1

ICP 100-English page 7

Article No 24264412

Sound pressure level LpA in dB(A)

Pump alone Pump + Motor

1450 min-1

975

min-1

2950 min-1

1450 min

-1

975

min

-1

18,5 69,0 68,5 68,0 73,0 70,5 74,0 22,0 70,5 69,5 69,0 74,5 71,0 74,0 30,0 72,0 71,0 70,5 75,0 72,0 73,0 37,0 73,0 72,0 71,5 76,0 73,5 73,5 45,0 74,0 73,0 72,5 77,0 74,5 73,5 55,0 75,5 74,5 74,0 78,0 75,5 75,0 75,0 77,0 76,0 75,5 80,0 76,5 76,0

90,0 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 --

Model ICP

Sound pressure level LpA measured in 1 m distance from 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 Torques at the Pump Nozzles ...

... following the Europump-Recommendation for pump acc. to ISO 5199.

The data for forces and torques are only valid for static piping loads. The values given in the chart are valid for pump units with standard-ICP-base frames (ungrouted). All values for forces and torques refer to standard materials EN-GJS400-18LT and 1.4408.

pic 1

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Model ICP

Sizes

40-25-160 40 1250 1100 1000 1950 1300 900 1050 1900 25 750 700 850 1300 900 600 700 1300 40-25-200 40 1250 1100 1000 1950 1300 900 1050 1900 25 750 700 850 1300 900 600 700 1300 40-25-250 40 1250 1100 1000 1950 1300 900 1050 1900 25 750 700 850 1300 900 600 700 1300

50-32-160 50 1650 1500 1350 2600 1400 1000 1150 2050 32 900 850 1050 1650 1100 750 850 1600 50-32-200 50 1650 1500 1350 2600 1400 1000 1150 2050 32 900 850 1050 1650 1100 750 850 1600 50-32-250 50 1650 1500 1350 2600 1400 1000 1150 2050 32 900 850 1050 1650 1100 750 850 1600 50-32-315 50 1650 1500 1350 2600 1400 1000 1150 2050 32 900 850 1050 1650 1100 750 850 1600

65-40-160 65 2100 1850 1700 3300 1500 1100 1200 2200 40 1100 1000 1250 1950 1300 900 1050 1900 65-40-200 65 2100 1850 1700 3300 1500 1100 1200 2200 40 1100 1000 1250 1950 1300 900 1050 1900 65-40-250 65 2100 1850 1700 3300 1500 1100 1200 2200 40 1100 1000 1250 1950 1300 900 1050 1900 65-40-315 65 2100 1850 1700 3300 1500 1100 1200 2200 40 1100 1000 1250 1950 1300 900 1050 1900

80-50-160 80 2500 2250 2050 3950 1600 1150 1300 2350 50 1500 1350 1650 2600 1400 1000 1150 2050 80-50-200 80 2500 2250 2050 3950 1600 1150 1300 2350 50 1500 1350 1650 2600 1400 1000 1150 2050 80-50-250 80 2500 2250 2050 3950 1600 1150 1300 2350 50 1500 1350 1650 2600 1400 1000 1150 2050 80-50-315 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 2200 100-65-200 100 3350 3000 2700 5250 1750 1250 1450 2600 65 1850 1700 2100 3300 1500 1100 1200 2200 100-65-250 100 3350 3000 2700 5250 1750 1250 1450 2600 65 1850 1700 2100 3300 1500 1100 1200 2200 100-65-315 100 3350 3000 2700 5250 1750 1250 1450 2600 65 1850 1700 2100 3300 1500 1100 1200 2200

125-80-160 125 3950 3550 3200 6200 2100 1500 1900 3050 80 2250 2050 2500 3950 1600 1150 1300 2350 125-80-200 125 3950 3550 3200 6200 2100 1500 1900 3050 80 2250 2050 2500 3950 1600 1150 1300 2350 125-80-250 125 3950 3550 3200 6200 2100 1500 1900 3050 80 2250 2050 2500 3950 1600 1150 1300 2350 125-80-315 125 3950 3550 3200 6200 2100 1500 1900 3050 80 2250 2050 2500 3950 1600 1150 1300 2350 125-80-400 125 3950 3550 3200 6200 2100 1500 1900 3050 80 2250 2050 2500 3950 1600 1150 1300 2350

125-100-200 125 3950 3550 3200 6200 2100 1500 1900 3050 100 3000 2700 3350 5250 1750 1250 1450 2600 125-100-250 125 3950 3550 3200 6200 2100 1500 1900 3050 100 3000 2700 3350 5250 1750 1250 1450 2600 125-100-315 125 3950 3550 3200 6200 2100 1500 1900 3050 100 3000 2700 3350 5250 1750 1250 1450 2600 125-100-400 125 3950 3550 3200 6200 2100 1500 1900 3050 100 3000 2700 3350 5250 1750 1250 1450 2600

150-125-250 150 5000 4500 4050 7850 2500 1750 2050 3650 125 3550 3200 3950 6200 2100 1500 1900 3050 150-125-315 150 5000 4500 4050 7850 2500 1750 2050 3650 125 3550 3200 3950 6200 2100 1500 1900 3050 150-125-400 150 5000 4500 4050 7850 2500 1750 2050 3650 125 3550 3200 3950 6200 2100 1500 1900 3050

200-150-250 200 6700 6000 5400 10450 3250 2300 2650 4800 150 4500 4050 5000 7850 2500 1750 2050 3650 200-150-315 200 6700 6000 5400 10450 3250 2300 2650 4800 150 4500 4050 5000 7850 2500 1750 2050 3650 200-150-400 200 6700 6000 5400 10450 3250 2300 2650 4800 150 4500 4050 5000 7850 2500 1750 2050 3650

∅DN

Forces in N Torques in Nm Forces in N Torques in Nm

Fx Fy Fz

Suction nozzle Discharge nozzle

Mx My Mz

∑F

∑M

∅DN

Fx Fy Fz

Mx My Mz

∑F

∑M

4. Transport, Handling, Storage

4.1 Transport, Handling

 Check the pump / pump unit immediately upon

delivery / receipt of despatch for damage or missing parts.

 The pump / pump unit must be transported care-

fully and by competent personnel. Avoid serious impacts.

 Keep the pump/pump unit in the same position in

which it was supplied from the factory. Take note of the instructions on the packaging.

 The suction and discharge side of the pump must

be closed with plugs during transport and storage.

Dispose of all packing materials in accordance with local regulations.

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

device, pulleys, sling ropes, etc.) must be sufficiently strong and must only be used by author-

ICP 100-English page 8

Article No 24264412

ized persons. The weight of the pump / pump unit is given in the data sheet.

 The pump / pump unit may only be lifted by solid

points such as the casing, flanges or frame. Picture 2 shows the correct method of carrying by crane.

pic 2

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Do not stand underneath suspended loads. Take note of the general regulations on prevention of accidents. The pump / pump unit must be secured against tipping over and slipping until it has been fixed in its final location.

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

Slipping out of the pump / pump unit of the transport lifting device can cause damages to persons and things.

5. Mounting / Installation

Model ICP

4.2 Storage / Conservation

Pumps or units, which are stored over a longer period before start-up (max. 6 months), must be protected from moisture, vibrations and dirt (e.g. by wrapping in oil paper or plastic). Pumps must basically be stored in a place where they are protected from the weather, e.g. under dry cover. During this time, all suction and discharge branches and all other intakes and outlets must be closed with dummy flanges or plugs. For longer periods of storage conservation measurements at machined surfaces and packing with moisture protection can be necessary!

5.1 Mounting of Pump / Unit

The pump and motor (= pump unit) must be provided with a base frame made of steel or cast iron or a fabricated (welded) frame, where this does not exist already or if it is not included in the delivery. This base frame must be placed on a foundation which can withstand all loads that arise during operation (refer to chapter 5.1.2).

When mounting the pump onto the base frame the following 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 is recommended). Bracing of the pump leads to premature breakdown of the pump and to a loss of warranty.

 The drillings for the pump mounting must be in

such a way, that safe fastening is guaranteed.

 Between pump and motor shaft an adequate

space must be left depending on the used coupling, refer to chapter 5.3.

5.1.1. Mounting the unit to a foundation

The place, where the pump is mounted must be prepared acc. to the dimensions of the dimensional drawings. The concrete foundations should have sufficient firmness acc. to DIN 1045 or equal standard (min. BN

15), to ensure a secure, functional mounting. The concrete foundation must have set, before the unit is errected. Ist surface must be horizontal and even.

Sufficient space must be provided for maintenance and repair work, especially for replacing the drive motor or the complete pump unit. The motor fan must be able to take in enough cool air, and the intake grille must therefore be at least 10 cm away from any wall, etc.

 For the set of anchor bolts according recesses

must be provided. If that is not the case, concrete expansion bolts resp. epoxy capsle anchor bolts can be used.

ICP 100-English page 9

Article No 24264412

 When mounting the pump on the foundation it

must be adjusted at the discharge nozzle by means of a spirit-level (at discharge nozzle). The permitted deviation is 0,2 mm/m. After inserting the foundation bolts they must be cast in the foundation with concrete. After setting of the grout the coupling alignment must be checked according chapter 5.3.1 and possible misalignments must be corrected by adjusting foundation frame in the area of the drive motor. The smoothness of the base frame must be 0,2 mm/m before it is filled up resp. fastened. For adjustment leveling shims or leveling screws (optional, not delivered standardwise) can be used. Levelling shims must be inserted next to the foundation anchors and must lie plainly. After that fasten foundation bolts symmetrically but only slightly. Fill in base frame with non shrinking 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 and firmly. Check alignment of coupling acc. to chapter

5.3.1 and re-adjust, if necessary. Further, check that all screws between pump / motor and the base frame fit snugly. Although the original ICP-base frames are designed solidly, the filling in of the adjusted base frame up to the rim is recommended.

 If vibrations are transmitted to the foundation from

adjoining components, it must be guarded through adequate vibration damping paddings (vibrations from outside can impair the bearing).

 To prevent vibrations being transmitted to adjoin-

ing components, the foundation should be laid on a suitable insulating base.

The size of these insulating pads will vary, depending on circumstances, and should therefore be determined by an experienced specialist.

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5.2 Connection of Pipings to the Pump

The pump must not be used as fixed point fo the piping. The permitted piping loads must not be 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 pump functions without problems. Particular attention is to be paid to ensuring that suction pipes are airtight and that the NPSH values are observed. Under suction lift condition lay the suction pipe in the horizontal section towards the pump so that it is slightly inclined upwards so that no air traps occur. Under positive suction head condition install the suction pipe work slightly declined towards the pump. Do not install fittings or elbows right before the suction nozzle.

 If the suction supply is under vacuum and en-

trained gas may be present in the liquid, it is recommended that a vent line be considered upstream of the pump suction with return to the suction supply, above the max liquid level.

 An additional flushed piping - discharge branch-

vent line - makes it easier to de-aerate the pump before start-up (pic 3).

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

is accessible for maintenance, installation and disassembly.

 Notice "Permitted Forces on Flanges" (chapter

3.5).

 If expansion joints are used in the pipes, they

have to be supported in such a way that the pump is not loaded unduely high because of the pressure in the pipes.

 Before connecting up to pump: remove protective

coverings from suction and discharge branches.

 Before starting up, the pipe system, fittings and

equipment must be cleaned to remove weld spatter, scale etc. Any pollutants are to be completely removed from pump units that are directly or indirectly connected to drinking water systems before being installed and taken into use.

 To protect the shaft sealing (especially mechani-

cal seals) against foreign impurities, it is recom-

ICP 100-English page 10

Article No 24264412

Model ICP

mended that a sieve, 800 micron, is installed in the suction/intake pipe when the motor is being started up.

 If the pipe system is tested with the pump in-

stalled, do not exceed the maximum permitted casing 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 (danger of rust and problems when starting up).

 In the case of pumps with stuffing boxes, replace

packing after pressure test (packing may be overcompressed and thus no longer suitable for use).

5.2.2 Additional connections

Any required sealing, flushing or cooling pipe connections must be installed. Please consult the data sheet to see which pipes, pressures and amounts are necessary. The position and size of connections to the pump are given in the appendix, "Connections".

These connections are essential for the function!

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

5.3 Coupling

Make sure that nobody can start the motor during work on the coupling.

ccording to Accident Prevention Regulations,

the pump unit may only be operated when the coupling guard is mounted.

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

The Operating Instructions of the manufacturer must be followed.

5.3.1 Alignment of coupling

The alignment of the coupling must be carried out with the utmost care and attention, so that the unit will operate without failure. If you do not pay attention to this hint you will lose your warranty!

 Before starting installation, carefully clean shaft

ends and coupling components.

 Before adjusting the coupling unfasten screws

(901.12) between bearing bracket (330) and casing foot (183) and only fasten again after the adjustment. Repeat measurement after fastening of screws (901.12).

fter mounting onto the foundation and the

connection of the pipings the coupling must be adjusted again, even, if the unit was delivered completely mounted on the frame.

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 The unit is properly aligned, when a ruler, which is

laid axially over both coupling halves, has the same distance to the particular shaft everywhere on the circumference. Further, both coupling halves must have the same distance to one another on every of the circumference. This must be checked by means of a tracer, gauge or dial gage; refer to pic. 4 and 5.

 The permitted tolerances for your coupling is

shown in the operating instructions of the coupling. For the exact characterization of your coupling refer to data sheet and / or order confirmation.

Model ICP

ruler

gauge

pic 4 - Alignment of coupling with gauge and ruler

ruler

pic 5 - Alignment of coupling with spacer

gauge

Control alignment of coupling again in operation warm condition and on system pressure (i available) and correct, if necessary. Pay attention to chapter 6 beforehand! It must be possible to turn the unit easily and harmoniously by hand.

Improper alignment of the unit can lead to damages at coupling and unit!

Mount coupling guard after alignment and before start-up.

5.3.2 Coupling Guard

cc. to accident prevention regulations the pump must only be operated with coupling guard.

Parts:

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

Assembly:

ICP 100-English page 11

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5.4 Drive

On selecting the motor size care has to be taken, that the requirements acc. to ISO 5199 are fulfilled. Note

the Operating Instructions of the motor manufacturer.

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

5.5 Electric Connection

6. Start-up, Operation, Shut down

Model ICP

Electrical connection work may only be carried out by an authorised professional. The rules and regulations valid for electrical technology, especially those concerned with safety measures, must be observed. The regulations of the national power supply companies operating in that area must also be observed.

Before starting work, check that the information on the motor name plate is the same as the local mains network. The power supply cable of the coupled drive motor must be connected up in accordance with the wiring diagram produced by the motor manufacturer. A protective motor switch must be provided.

In areas endangered to explosion IEC 6007914 must additionally be noticed for the electric installation.

Care must be taken that the base frame (2x M10-thread available for earthing screws) is earthed by means of corresponding measures.

The direction of rotation must only be checked when the pump is full. Dry running will cause damage to the pump.

5.6 Final Control

Check alignment of coupling acc. to chapter 5.3.1 again. It must be possible to turn the unit easily by hand at the coupling.

The plant may only be started up by people who are familiar with the local safety regulations and with these Operating Instructions (especially with the safety regulations and safety instructions given here).

6.1 Initial start-up

Before starting up the pump, check, if the following points 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 oil as 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 completely

with liquid when starting up.

 Turn pump unit once again by hand and check

that it moves smoothly and evenly.

 Check that coupling guard is installed and that all

safety devices are operational.

 Switch on any sealing, flushing or cooling devices

that are provided. See data sheet for quantity and pressure.

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

flow quantity. With pumps with a discharge branch

rated width less than 200, the valve can remain closed when starting up.

 Secure, that unit is electrically connected acc. to

all regulations and with all safety devices.

 Check direction of rotation by switching on and off

briefly. It must be the same as the directional arrow 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) after reaching normal operating speed open discharge valve adjust the required operating point. The pumping data shown at the type plate resp. in the data sheet and / or the order confirmation must be met. Every change is only permitted after talking with the manufacturer!

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

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

ICP 100-English page 12

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In order that the shaft sealing can be monitored and maintained unhindered, no protection cove is provided in this area. Therefore special attention is required when pump is working (no long hair, loose clothes, a.s.o.).

 Packing:

Packings need leakage for troublefree function (dropwise outlet of pumped medium). Adjust ample leakage in the beginning. Reduce that slowly during the first operating hours by continuously fastening of gland (see position "452" and "920.31" in sectional drawing) when pump is running. Assume 30-100 drops / minute as approx. value.

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

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

6.3 Restarting

Basically, the same procedure should be followed as for starting up for the first time. However, there is no need to check the direction of rotation and the accessibility of the pump unit. The pump should only be automatically restarted if it has been made sure that the pump has remained filled whilst stand by.

Be particularly careful not to touch hot machine parts and when working in the unprotected shaft seal area. Remember that automatically controlled systems may switch themselves on suddenly at any time. Suitable warning signs should be affixed.

6.4 Limits of Operation

The operating limits of the pump / unit regarding pressure, temperature, performance and speed are shown in the data sheet and / or order confirmation and must be observed under any circumstances!

 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:

= 0,1 x Q

min

= 0,3 x Q

min

= 1,2 x Q

max

= Flow in efficiency optimum

BEP

*) on condition that NPSH

ICP 100-English page 13

Article No 24264412

for for short time operation

BEP

for continuous operation

BEP

for continuous operation *)

BEP

facility

> (NPSH

+ 0,5 m)

pump

Model ICP

6.4.2 Abrasive Media

On pumping liquids with abrasive components an increased wear at hydraulic and shaft sealing must be expected. The intervals of inspection should be reduced compared to the usual times.

6.4.3 Permitted number of starts

The permitted number of starts of the pump must not be exceeded, see diagram 6.

100,0

10,0

max. perm. starts/h

1,0

1 10 100 1000

Motor power [kW]

diagram 6 With electric motors, the permitted number of starts is

given in the attached motor operating instructions. If two different figures are given, the lower figure is valid.

6.5 Lubrication of Bearings

6.5.1 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 oil into the connection opening (GF1). Fill in oil up to the middle of the oil level sight glass (642) (pic 7). Keep level exactly. Overfilling leads to increased bearing temperature and possibly oil leakage. If oil level is too low this can cause shortcoming of lubrication.

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 for constant level oiler (638). Tighten until threaded boss is in vertical position (picture 8).

 Remove the oil filling plug (637) (upper side of

bearing bracket) and fill in oil through the connection opening (GF1), until the oil level reaches al-

pic 7

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most the middle of the oil level sight glass in the main 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

insert the spout into the internal threaded boss on the main body. Tighten reservoir (picture 8).

 Now the oil is flowing from the reservoir into the

bearing chamber.

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

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 of bearing bracket).

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

bracket) should lie max. 50°C over ambient temperature and must not exceed 90°C, control weekly at least. On grease lubrication the bearing temperature can temporarily be higher by 5-10°C after regreasing, till a possible surplus of grease in the bearings is cut.

6.6 Monitoring

In areas endangered to explosion it is recommended to monitor the temperature of the bearings and the vibrations of the bearing bracket.

Regular monitoring and maintenance will extend the life of your pump or pump system.

 Check oil level at least once a week and top up if

necessary.

 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 a week to ensure that they function properly. Outgoing cooling water should be handwarm.

 With double mechanical seals, monitor pressure

and flow rate in mechanical seal area; check at least once a week.

ICP 100-English page 14

Article No 24264412

Model ICP

 Pumps which are exposed to corrosive chemicals

or to wear through abrasion must be inspected periodically for corrosion or wear and tear. The first inspection should be carried out after six months. All further inspection intervals should be determined 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 is not necessary if there is a spring-loaded check valve.

 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 stationary,leave all sealing, flushing and cooling systems switched on.

 The shaft sealing must remain sealed if there is a

risk of air being sucked in (in the event of supply from vacuum systems or parallel operation with shared suction pipe).

6.8 Storage / longer periods of nonoperation

6.8.1 Storage of new pumps

If the putting into operation shall happen a longer period after the delivery, we recommend the following measures 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 operation

Pump remains installed and in ready for operation:  Test runs of 5 min. duration must be made in

regular intervals. The span between the test runs is depending on the plant. However, it should be made once a week, at least.

6.8.3 Longer periods of non-operation

fter long stationary periods, packings may have hardened; these must be replaced before start-up. When starting up, follow the instructions fo starting 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 cooling 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).

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b) Drained pumps

7. Servicing, Maintenance

Model ICP

 Turn shaft at least 1x week (do not switch on be-

cause of dry running).

 Replace oil or grease after 2 years.

7.1 General remarks

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

Maintenance and servicing work must only be carried out by trained, experienced staff who are familiar with the contents of these Operating Instructions, or by the Manufacturer's own service staff.

7.2 Mechanical seals

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

If the liquid being handled leaks out at the mechanical seal, it is damaged and must be replaced. Replacement of the mech. seal according to accompanying "Mounting Instructions for Shaft sealing".

7.3 Stuffing boxes

Stuffing boxes require constant maintenance, see chapter 6.2 section "Stuffing box". If the leakage rate can no longer be set correctly, the packing is worn out and must be replaced in good time (increased wear on shaft sleeve). Replacement of stuffing boxes acc. to attached "Mounting Instructions for Shaft Sealing".

Because of the risk of accidents, addition of packing to pumps during operation or at operating pressure or temperature is strictly forbidden!

7.4 Lubrication and Change of Lubricant

7.4.1 Oil lubrication

All further oil

changes

after ..... operat-

ing hours

Temperature at

bearing

First oil change

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 oil changeing intervals must be kept under any circumstances!

Oil changing

 After the first ....... operating hours, drain oil (oil

drain "GD" with drain plug 903.51) and flush with fresh oil. Clean oil drain plug and close oil drain again.

 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 with the valid national environmental regulations.

Oil quality

Lubricating oil

Name

CLP46

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 mm

+175°C

higher than permit-

-15°C

ted bearing tem-

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

perature

Oil quantity

Bearing bracket Oil quantity in l

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

7.4.2 Grease lubrication Re-greasing

 Grease lubricated bearings with the possibility of

re-greasing must be re-lubricated all 4000 operating hours, but at least 1x year. Clean lubricating nipples (636) first.

Quality of grease lubricant ...

... corresponding to NLGI GRADE 2

Quantity of re-greasing (approx. value)

Bearing bracket

bearing at pump

side

bearing at drive

side 24 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 longer

time, the grease in the bearings should be changed after 2 years.

7.5 Coupling

Check the clearance in the coupling components regularly approx. every 1000 operating hours, but at

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least 1x year, the radial clearance in the coupling parts must be checked. For couplings with rubber pads the following applies: Unless a clearance in the couplings is necessary, the coupling pads may wear out to approximately ¼ of their usual thickness, before they have to be changed. To measure the clearance in the coupling place a mark on the O.D. of each coupling hub (see following pic). Then fixing one hub, turn the opposite hub as far as possible. Then measure the distance (∆S tween the marks of the coupling. If this measure exceeds the value given in the chart, the packings must be 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 the motor is not properly aligned with the pump o

) be-

Model ICP

that the distance between the coupling sections has changed. Replace worn elements and reinstall or adjust coupling, as described in chapter 5.3.

7.6 Cleaning of pump

The pump must not be cleaned with pressurised water - water will get into the bearings.

 Dirt on the outside of the pump has an adverse

effect on transmission of heat. The pump should therefore be cleaned with water at regular intervals (depending on the degree of dirt).

 Radial-Shaft sealings (421.41 and 421.51) are not

completely free from leakage. Impurities could cause leakage at the shaft sealing area of the frame. Therefore wipe off impurities with a rag from time to time.

 Replace dirty oil level sight glass (642).

8. Dismantling and repair of pump

8.1 General remarks

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

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

For mounting and repair you can order specialized personnel if you want.

If dangerous liquids are pumped the appropriate disposal of the handled liquid is necessary before the disassembly of the pump. Pay attention to the fact, that even in drained pumps there are remainders of the handled liquid. I necessary the pump must be flushed or decontaminated. Laws must be observed, otherwise danger to health 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 single parts against tipping over or rolling off.

While disassembling the pump use of an open flame (blowlamp, etc.) only, when there is no danger of setting fire, cause an explosion o cause injurious vapours. Never apply heat to remove the impeller nut. Use of heat may result in severe physical injury and property damage.

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

8.2 General

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

Carry out disassembly and mounting according to the appropriate 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 the replacement of the repair part.

8.3 Disassembly of Back Pull Out Assembly

The Back Pull Out Assembly includes all parts of the pump except the volute casing (102V). As the pumps are 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).

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 Unscrew pipe unions of all flush- and cooling-

water-pipes and drain lubrication oil from bearing bracket (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 the volute casing during the dismounting. Example see picture 9 for lifting recommendations.

Model ICP

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

ing.

 Using the jack screws provided (901.42), sepa-

rate the Back Pull Out Assembly from the casing.

8.4 Removal of Impeller

Note attached "Mounting Instruction for Shaft Sealing".

 If the impeller has back vanes check the axial

clearance "a" between the impeller (230) and casing cover (161) before you continue the dismounting. Refer to sect. 8.7.1.

 Loosen impeller nut (922) (right threaded) by fix-

ing the rotor at the coupling end.

 Draw off the impeller (230) with two screw drivers

or pry bars (picture 10). Remove key (940.31).

pic 10

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

 For further dismounting the Back Pull Out Assem-

bly should be placed in the vertical position (with vertical shaft, see picture 11). Attention: Precautions should be taken to prevent the Back Pull Out Assembly 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 of bearing 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 screw drivers (see pic 13).

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Model ICP

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

bearing bracket lantern from bearing bracket (330).

 Dismount circlip (932.51). Therefore you need a

snap ring plier acc. to DIN 5256-C.

Bearing

bracket

required snap ring

plier

length i (min.) of

snap ring plier

24 size 94/C 40 200mm

32, 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 nut

is right hand threaded and self locking. It can be reused 5 times if it is handled appropriately.

 Remove the anti-friction bearing (320.51 and

320.52) from the shaft (210) using a hydraulic press or a bearing puller.

8.7 Reconditioning

After disassembly all parts must be cleaned and checked for wear carefully. Worn or damaged parts must be replaced by new parts (spare parts). When reassembling the pump it is recommended to replace all seals.

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

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

8.7.1 Clearance at impeller

Suction side of impeller Back vanes of impeller

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Drive side of impeller

Only for pump sizes 100-65-315 125-80-315 125-80-400 125-100-315 125-100-400 150-125-315 150-125-400 200-150-315 200-150-400

Nominal diameter D (mm) Radial

clearance s (mm)

clearance a (mm)

100 120 135

60 68

new wear limits 0,78 0,85 0,90 1,05 1,15

new 0,8 - 1,2 Axial wear limits max. 1,7

min. 0,15 0,17 0,20 0,22 0,25 max. 0,19 0,22 0,24 0,27 0,30

When the wear limits has been reached or exceeded, 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 correct 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. Please contact factory for details.

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

8.8 Mounting

Re-assemble the pumps using the reverse order of steps as completed for pump disassembly. However the 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-galling compound (e.g. Molykote/Never-Seeze), so that the assembly and the next disassembly will be easier.

Anti-galling compound must be compatible with the pumpage.

155

220

175

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 Screws should be tightened, with the following

torque:

Location

Casing screws

All other screws

Screw

Size M12 35 50

M16 105 150 M20 210 305 M10 35 50 M12 60 90 M16 150 220

 Before mounting the second bearing on the shaft

push in the circlip (932.51) between the two bearings.

 Before mounting new bearings, warm them up to

80°C in an oil bath or using a bearing heater. If necessary use a tube to force the inner ring onto the shaft by gentle taps with a hammer. Hold the outer ring to avoid vibrations of the balls.

 When bolting together the bearing bracket (330)

with the bearing bracket lantern (344) and the bearing bracket lantern with the volute casing (102V), screws should be positioned in the centre of the drilled holes. Failure to do so could result in improper oil setting.

 Push the flinger (507) onto the shaft (210) till it

rests axially against the shoulder of the shaft. Between flinger (507) and Bearing bracket lantern (344) there must remain a clearance of at least 0,7 mm.

 If necessary you can use a driver for mounting

(see picture 14).

Screw torque in Nm

Lubricated

threads

Dry threads

Drive

pic 14

Model ICP

 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 chapter 8.5.

 For impellers with back vanes the axial clearance

between the back vanes and the casing cover (161) should be checked after mounting the impeller (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 the shaft and control the free moving of the pump in this way. The shaft sealings will cause slightly resistance when turning, but there must not be any contact between metal parts.



Before starting the pump check alignment of the coupling. This can be dropped on pumps with spacer coupling, if pump casing and motor were not disassembled.

Before starting the pump do not forget to fill in oil!

9. Recommended Spare Parts, Spare Pumps

9.1 Spare Parts

Spare parts should be selected to last for two-years continuous operation. If no other guidelines are applicable, we recommend that you stock the number of parts listed below (in accordance with DIN 24296).

Number of 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 casing sets other joints sets 4 6 8 8 9 10 100% Mech. Seals set 1 1 2 2 2 3 25% Bearing (lantern with bearing bracket, complete with shaft, bearings, aso.)

4 6 8 8 9 12 150%

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Article No 24264412

(incl. stand-by pumps)

- - - - - - 2

Spare Parts Order

When ordering spare parts, please supply the following information:

 Type:  S/N (Order No.):  Part name:  Sectional Drawing

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

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

To ensure optimum availability, we recommend that suitable quantities of spare parts are held in stock, especially if these are made from special materials and in the case of mechanical seals, because of the longer delivery times.

______________________________________________________________________

___________________________________________________

_____________________________________________________________

__________________________________________________

Store spare parts in dry and clean rooms!

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9.2 Stand-by pumps

It is essential that a sufficient number of standby pumps are kept ready for use in plants where failure of a pump could endanger human life or cause damage to property or high costs. Regular checks should be carried out to ensure that such pumps are always ready for use (see chapter 6.8).

10. Faults - Causes and Solutions

The following notes on causes of faults and how to repair them are intended as an aid to recognising the problem. The manufacturer's Customer Service Department is available to help repair faults that the operator cannot or does not want to repair. If the operator repairs or changes the pump, the design data on the Data Sheet and chapter 2 of these Operating Instructions should be particularly taken into account. If necessary, the written agreement of the manufacturer must be obtained.

Model ICP

Store stand-by pumps according to chapter 6.8.

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Model ICP

Discharge too low

Discharge stops after a time

Head too low

Head too high

Drive mechanism overloaded

Pump not running quietly

Temperature in pump too high

■

Back-pressure too high

■

■ ■

■ Flow too big reduce flow (throttle discharge valve)

■ ■

■ ■ ■

■ ■

■ ■ ■

■ ■

■ ■ ■

■ ■Stuffing box not straight tighten evenly

■ Stuffing box is fastened too tight resp. shaft sealing is

■ ■Lines and roughness on shaft or shaft sleeve replace parts

■ ■Unsuitable packing material use suitable material (check shaft or shaft sleeve for damage

■ ■Deposits on mechanical seal

■ ■Impeller out of balance

■ ■

■ ■ Coupling distance too small change

■ Too much, too little or the wrong type of lubricant change

■ Electricity supply not right (2-phase running) check voltage of all phases

■ Sealing insufficient tighten screws

■ ■ Bearing damaged replace

■ Relief fittings insufficient

■ System-related vibrations (resonance) seek assistance

■

■ Back-pressure too low, discharge too low throttle discharge valve

■ ■

Speed too high reduce speed

Speed too low increase speed (check available motor power)

■ ■

Impeller diameter too big use smaller impeller

Impeller diameter too small use larger impeller (check available motor power)

■ ■

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

■ ■

Air being sucked in increase liquid level Air being sucked in through shaft sealing clean sealing pipe

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

■ ■ Inner components suffering from wear replace worn parts Density and/or viscosity of liquid handled is too high seek assistance

■ ■

Temperature in shaft sealing too high

Flow too little increase min. flow (open discharge valve, bypass)

Pump and/or pipes not completely filled with liquid fill

Suction height too big / NPSH of system too small

■ ■ ■

Cause

Temperature at the bearing too high

Pump leaking

Leakage rate at shaft sealing too high

worn

■

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

Solution check facility for pollution, open discharge valve

reduce resistance in discharge pipe (e.g. clean filter if necessary) use larger impeller (note available motor power)

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

compare speed of motor with specified pump speed (rating plate) when adjusting speed (frequency transformer) check reference value settings

vent

improve course of pipe increase liquid level and admission pressure reduce resistance in the intake/suction pipe (change course and rated width, open shut-off valves, clean filters)

check if suction pipe is vacuum-tight increase sealing pressure

replace shaft sealing electrician)

loosen stuffing box replace packing and/or mechanical seal check sealing, flushing and cooling pipes (pressure) avoid dry running

beforehand) clean replace mechanical seal if necessary if necessary provide additional rinsing or quench remove blocks/deposits replace impeller if broken or unevenly worn check shafts to ensure that they are running true

is foundation plate/frame properly cast in place?

check cable connections and fuses replace sealing check lubricant and bearing space for pollutants (rinse oil

area) clean relief openings in impeller replace worn parts (impeller, split rings) adjust in line with the system pressure/intake pressure given on ordering

ICP 100-English page 21

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Keep for further use !