Fristam Pumps FP Series, FP, FP V Series, FPE Original Instructions, Assembly Instructions
Original Instructions
Assembly Instructions
Centrifugal Pump
FP Series
Pump Type:
Pump No.:
Copyright
© Copyright 2012 Fristam Pumpen KG (GmbH & Co.)
All rights reserved. The contents, including graphic images and layout of this operating instructions manual are
subject to copyright protection and to other laws for the protection of intellectual property. The publication and
modification of the contents are not authorised. Moreover, you may not copy, publish and alter the contents therein for commercial purposes, or transmit the information to a third party.
The German version is the original version of the operating instructions manual. Other languages are translations of the original operating
manual.
Table of Contens
1 Introduction............................................... 5
1.1 Foreword................................................................... 5
1.2 Manufacturer........................................................... 5
1.3 Scope of Supply...................................................... 5
1.4 Pump Without Motor (Optional)...................... 5
1.5 Scope of Documentation.................................... 5
1.6 Display Conventions............................................. 5
2 Safety.......................................................... 6
2.1 Basic Safety Instructions...................................... 6
2.2 Intended Use ........................................................... 6
2.3 Improper Use........................................................... 6
2.4 Warning and Instruction Labels........................ 6
2.5 Noise Emissions ...................................................... 6
2.6 Disposal ..................................................................... 7
3 Design and Function ................................. 7
3.1 Principles of Design............................................... 7
3.2 Models ....................................................................... 8
3.3 Pump Key.................................................................. 9
3.4 Versions ..................................................................... 9
4 Transportation........................................... 9
4.1 Transportation ........................................................ 9
5 Storage ....................................................... 10
5.1 Safety Instructions................................................. 10
5.2 Storage Conditions................................................ 10
5.3 Long-Term Storage ............................................... 11
5.4 Recommissioning .................................................. 11
6.6 Connection of Sealing or Quenching
Liquid (Optional) ................................................... 13
6.7 Cleaning.................................................................... 13
7 Operation .................................................. 13
7.1 Safety Instructions ................................................ 13
7.2 Commencement of Operation......................... 13
7.3 Monitoring of Operation .................................... 14
7.4 Stopping of Operation ........................................ 14
7.5 Pump Decommissioning.................................... 14
7.6 Cleaning in Place................................................... 14
8 Faults ......................................................... 14
8.1 Safety Instructions ................................................ 15
9 Maintenance ............................................. 15
9.1 Safety Instructions ................................................ 15
9.2 Replacement Parts................................................ 15
9.3 Inspection of Sealing and Quenching
Liquid (Optional) ................................................... 15
9.4 Lubrication of Motor Bearings.......................... 15
9.5 Lubrication of Shaft Bearing ............................. 15
9.6 Motor Replacement ............................................. 17
9.7 Shaft Seal Replacement ...................................... 18
9.8 Pump Head Removal .......................................... 18
9.9 Checking of the Clearances............................... 18
9.10 Pump Head Attachment..................................... 20
9.11 Models FPE and FP…V: Mounting and
Alignment of the Pump Shaft........................... 27
9.12 Model L: Coupling Replacement ..................... 27
10 Appendix 1 ................................................ 28
6 Installation................................................. 11
6.1 Safety Instructions................................................. 11
6.2 Installation Location ............................................. 11
6.3 Reduction of Noise and Vibration.................... 11
6.4 Pump Fixation......................................................... 11
6.5 Electrical Connection............................................ 12
10.1 Specifications.......................................................... 28
10.2 Maintenance Intervals1....................................... 28
10.3 Troubleshooting Table........................................ 29
10.4 Number Key ............................................................ 31
10.5 EC Declaration of Conformity........................... 33
10.6 EG Declaration of Incorporation...................... 33
3
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11 Appendix 2 – Assembly Instructions
(Optional) ................................................... 34
11.1 Safety Instructions................................................. 34
11.2 Scope.......................................................................... 34
11.3 Rating Plate.............................................................. 34
11.4 Moving Without Motor........................................ 34
11.5 Installation Location ............................................. 35
11.6 Pump Installation................................................... 35
4
1Introduction
1.1 Foreword
This operator's manual describes all FP centrifugal pump sizes,
models, and versions.
Information on the model, size, and version of your pump can
be found on the rating plate on your pump and in the "Order-
Related Documents" in the attached documents.
1.2 Manufacturer
FRISTAM Pumpen KG (GmbH & Co.)
Kurt-A.-Körber-Chaussee 55
21033 Hamburg
GERMANY
Tel.: +49-40 - 72556 -0
Fax: +49-40 -72556 -166
E-mail: info@fristam.de
1.3 Scope of Supply
– Documentation on Fristam accessories (if applicable)
– Certificates (materials certificates, etc.), if applicable
– Declaration of Conformity or Declaration of Incorporation
1.6 Display Conventions
List items are preceded by dashes:
–Part 1
–Part 2
Handling instructions that must be performed in a specified
order are numbered:
1. Turn device on.
2. Turn device off.
Handling instructions that do not need to be performed in a
specified order are preceded by triangular bullets:
► Action
► Action
1.6.1 Safety Instructions
The package includes the following items:
– Pump with motor = pump unit
optional: without motor
– Covers for pipe fittings
– Optional: assembly kit
– Fristam accessories (if applicable)
– Documentation
► Check the shipment for completeness and damage.
Immediately notify Fristam of any missing items or damage.
1.4 Pump Without Motor (Optional)
The pump can optionally be supplied without a motor. In this
case, continue reading up to and including Chapter 3, "Design
and Function," page 7, and then skip to Chapter 11, "Appendix 2 –
Assembly Instructions (Optional)," page 34.
1.5 Scope of Documentation
The documentation includes the following items:
– This operator's manual
– Appendix 1 with maintenance, lubrication, and tighten-
ing torque tables
– Appendix 2 with assembly instructions
– Attached documents:
– Order-Related Documents
– Supplier Documentation (motor, coupling, etc.)
A safety instruction with the signal word "Danger" indicates
personal hazards causing death or serious injury.
A safety instruction with the signal word "Warning" indicates
personal hazards that may lead to death or serious injury.
A safety instruction with the signal word "Caution" indicates
personal hazards that may lead to mild to moderate injuries.
A safety instruction with the signal word "Note" warns of the
possibility of material damage.
5
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1
2
3
5
4
6
7
8
9
10
2 Safety
2.1 Basic Safety Instructions
► Please read this operator's manual completely before using
the pump and keep it available at the pump installation
location.
► Heed the applicable national regulations of the owner's
country and the company's work and safety regulations.
► All work described here may only be performed by qualified
experts with caution.
► Danger of contamination: Heed legal and operational safety
regulations when pumping dangerous media.
2.2 Intended Use
The standard FP centrifugal pump versions are designed for use
in the food industry, the pharmaceutical and biotechnology
industry, and CIP process technology.
They can be used to pump liquids with dynamic viscosities of up
to 1200 mPa s and media temperatures of up to 150°C. The
medium can contain a slight amount of air or gas, be
homogeneous, or contain a small amount of additives.
Each pump is designed according to customer requirements.
The seal materials have been selected for the respective
medium. The pump may only be used to pump the medium it
was designed for (see “Order-Related Documents“ in the attached
documents).
2.4.2 Hot Surface
Fig. 2Safety label: "Hot Surface"
This label indicates that parts can become hot during operation
or, if applicable, that hot media is being pumped. Only touch
the pump if you are wearing suitable gloves.
2.4.3 No Dry Running
Fig. 3Safety label: "No Dry Running"
This label indicates that the pump cannot be run dry. There
must always be medium in the suction line and the pump when
the pump is started. Otherwise, the pump will be damaged.
2.4.4 Rating Plate
2.3 Improper Use
The standard FP centrifugal pump versions may not be used in
explosive atmospheres. Special explosion-proof versions are
available for this.
Pumping of media other than those specified can destroy the
pump.
Standard pump units from Fristam are described in this
operator's manual. If nonstandard items or extras are installed,
the operator assumes the responsibility for operation.
Modifications and changes to the pump are only permissible
with the explicit consent of Fristam.
2.4 Warning and Instruction Labels
► Do not alter or remove the labels on the pump.
► Immediately replace damaged or lost labels with ones that
are true to the originals.
2.4.1 Direction of Rotation
Fig. 1 "Impeller Direction of Rotation" label
This label shows the direction of rotation of the impeller. It is
located at the front on the pump cover.
Fig. 4 Pump unit rating plate
Manufacturer
1
Type: pump series, pump size, model, version
2
SN: serial number of the pump
3
H: discharge head [m]
4
P: motor output [kW]
5
Year of manufacture
6
mttl: mass (total) [kg]
7
nR: rated speed [1/min]
8
Q: flow rate [m³/h]
9
CE mark
10
2.5 Noise Emissions
► The local noise exposure regulations must be complied with.
For noise emission values for the pumps, please see
Chapter 10.1, "Specifications," page 28.
6
Noise Generated by Running Pump
B
C
A
11
12
13
14
15
16
Hearing damage.
► Wear ear protectors when using pumps with specified sound
pressure levels of greater than 80 dBA.
2.6 Disposal
2.6.1 Disposal of Transportation Package
► Recycle the transportation package.
2.6.2 Models KF and L 1: Disposal of Grease
► Dispose of grease and objects saturated with grease in an
environmentally friendly manner in accordance with applicable regulations.
2.6.3 Models L 2, L 3/L3V, L 4V: Disposal of Lubricating Oil
► Dispose of oil and objects saturated with oil in an
environmentally friendly manner in accordance with
applicable regulations.
3 Design and Function
3.1 Principles of Design
Fig. 5 Principles of design of pumps illustrated using the FPE model
Pump head
A
Lantern
B
Electric motor
C
3.1.1 Pump Head (A)
2.6.4 Disposal of Pump
1. Carefully clean the pump. Dispose of residues in an
environmentally friendly manner in accordance with
applicable regulations.
2. Dismantle the pump into its constituent parts.
3. Dispose of the pump parts in an environmentally friendly
manner in accordance with applicable regulations.
2.6.5 Disposal of Electrical and Electronic Scrap
► Dispose of electrical and electronic scrap in accordance with
applicable directives.
Fig. 6Pump head
Discharge line connection
11
Shaft seal
12
Impeller
13
Pump cover
14
Suction line connection
15
Pump casing
16
Shaft Seal (12)
Two seal types are available for use:
– Single shaft seal
– Double shaft seal
With the double shaft seal, there are two additional connections for the sealing liquid on the pump casing. These connections are not shown in the following figures.
7
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17
18
19
20
Impeller (13)
Open impellers are standardly used in the FP pump series.
Pump Cover (14)
The connection for the suction line is located on the pump
cover.
Pump Casing (16)
The connection for the discharge line is located on the pump
casing. The impeller and the shaft seal are built into the pump
casing.
3.1.2 Lantern (B) and Electric Motor (C)
Electric Motor (19)
The following motor types can be mounted:
– IEC standard motor with drive side fixed bearing (A side),
feather key and shaft pin of the following types:
– IM B3: model with base
– IM B5: model with flange
– IM B3/5: model with flange and base
With the IEC standard motor, a Fristam pump shaft is
clamped to the motor shaft pin.
–Special motor with Fristam pump shaft
With the special motor, the Fristam pump shaft is already integrated and connected permanently to the motor.
3.2 Models
The model is indicated on the rating plate. See Chapter 2.4.4,
"Rating Plate," page 6.
The following are shown as examples:
– Lantern clamp-mounted
–Without enclosure
See Chapter 3.4, "Versions," page 9.
Fig. 7 Lantern and electric motor
Lantern
17
Electrical connection
18
Electric motor
19
Pump shaft
20
Lantern (17)
The lantern is present in all models except the special motor.
The lantern connects the pump casing to the motor. Two
different versions are possible, depending on pump size:
– The pump casing is screwed to the lantern via a flange con-
nection.
– The pump casing is inserted into the lantern and mounted
with a clamp.
Models with lanterns:
– FPE and FP…V
–KF
An additional bearing for the pump shaft is located inside
the lantern with base.
–L
An additional bearing for the pump shaft is located inside
the lantern with base. The pump shaft is connected to the
motor via a coupling.
3.2.1 Model FP
Fig. 8Model FP
Motor: Special motor
Design: Without lantern
3.2.2 Model FPE or FP…V
Fig. 9 Model FPE or FP...V
Motor: IEC standard motor, model B3/B5
Design: With lantern
8
3.2.3 Model KF
21 23 2422
Fig. 10 Model KF
Motor: IEC standard motor, model B5
Design: Compact bearing support with base
3.2.4 Model L
Fig. 11 Model L
(24) Supplementary Character 2
A, B ,C ,D Versions; see Chapter 3.4, "Versions," page 9:
KF Compact bearing support with base
L1, L2, L3
Bearing block with coupling
V Stainless steel lantern, double shaft seal,
ø75mm at lantern neck
H Pump casing with heating jacket
h Pump cover with heating jacket
3.4 Versions
Version Enclosure Spherical Cap
Legs
A With With Without
B Without Without With
C Without With Without
D With Without With
Table 1 Versions
Motor Foot
Motor: IEC standard motor, model B3
Design: Bearing block with coupling, coupling
protection, base frame
3.3 Pump Key
Fig. 12 Type designation example
Pump type
21
Supplementary character 1
22
Pump size
23
Supplementary character 2
24
(21) Pump Type
FP Special motor with extended motor shaft
FPE Attached pump shaft
FP...V Extended insert shaft as pump shaft
(22) Supplementary Character 1
S Open impeller with large clearance to casing
R Semiopen impeller with large clearance to
cover
H High-pressure pump
X Impeller for high pressures
Z Casing with circulation line
Note: If the (optional) pump without motor is supplied, please
first read Chapter 11, "Appendix 2 – Assembly Instructions
(Optional)" on page 34.
4Transportation
4.1 Transportation
Transportation may only be performed by trained personnel.
The pump can be moved using an industrial truck or a crane.
Always move the pump in the installation condition.
4.1.1 Safety Instructions
► Danger of injury from falling or unsecured parts.
– Only use suitable means of conveyance and hoists. Infor-
mation on pump weight can be found on the pump's rating plate as well as in the “Order-Related Documents“ in
the attached documents.
– Before moving the pump secure it to prevent it from tip-
ping over. Secure the pump to the pallet with tie-down
straps, or screw the pump to the pallet.
– Do not leave the pump in a raised position for longer
than necessary.
► Damage to pump by contamination, impact, or moisture.
– Remove the protective film just prior to installation.
– Remove the pipe fitting covers just prior to connection to
the pipes.
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4.1.2 Moving With Industrial Trucks
Preparation
► Ensure that the pump is adequately secured to the pallet.
Procedure
1. Pick up the pallet with the forks on the industrial truck.
2. Carefully move the pallet to the designated location and set
down.
Fig. 13 Moving with industrial truck
4.1.3 Moving With Crane
Falling Parts
Death from crushing, pinching of extremities, material damage.
► Do not lift the pump at the eyebolts on the motor and pump
casing to move because these eyebolts are not designed for
the total weight.
► Only use hoists that are designed for the total weight of the
pump.
► Ensure that the area below the pump is clear of people.
3. Guide both loops to the crane hook and rotate by 180° to ensure that the belt will not slip on the hook.
4. For double shaft seal:
Note: Round sling compresses sealing water tubes. Material
damage to double shaft seal.
► Do not lay the round sling on the sealing water tubes.
5. Position the center of gravity to ensure that the pump is lifted horizontally.
6. Lift the pump.
.
Fig. 14 Moving with crane
5Storage
5.1 Safety Instructions
Swinging Parts
Crushing and serious injuries.
► Start and stop the crane with pump smoothly.
► Ensure that the danger zone of the pump is clear of people.
Auxiliary Equipment
Hoists: round slings tested in accordance with DIN EN 1492-1
and 1492-2
Preparation
► Remove load-securing devices.
Procedure
1. Wrap the round sling twice around the back end of the
motor. Do not lay over the fan shroud (see
Fig. 14 Moving
with crane).
2. Lay the other end of the round sling between the lantern
and the pump casing. Do not lay the round sling over any
sharp edges or corners.
► Corrosion: Condensation can build up under a tarp and
destroy the pump.
– Ensure adequate ventilation.
5.2 Storage Conditions
► Store the pump as follows:
– Dry, in low humidity
– Protected against frost and heat, optimally at a tempera-
ture of 20°C to 25°C
– Ventilated
–Dust-free
10
5.3 Long-Term Storage
6.2 Installation Location
For a storage time of longer than six months, heed the
following:
► The shaft seals must be specially treated before long-term
storage:
– For single shaft seal
The impeller nut must be loosened so that the seal can
relax and the elastomers do not stick together.
– For double shaft seal
Remove the complete shaft seal and store separately to
prevent the elastomers from sticking together.
Information on the shaft seal can be found in the “Order-Re-
lated Documents“.
► All movable pump parts must be rotated every three
months.
5.3.1 Storage of Elastomers
Storage Conditions
– Storage temperature between +5°C and +20°C
– Relative air humidity below 70 %
– No direct sunlight
– Deformation-free storage
5.4 Recommissioning
► After long-term storage and before commissioning, check
seals, bearings, and lubrication.
6Installation
For standard pumps, the installation location must meet the
following requirements:
– Nonexplosive atmosphere
– Dust-free environment
– Ambient temperature: –20°C to +40°C
– Moisture and salt contents in ambient air:
The values are given in the motor supplier documentation. It
can be found in the attached documents.
– Foundation sized adequately for the pump weight
– Horizontal and level installation surface, adequate installa-
tion surface strength for pump mass
– Adequate clearance for maintenance work
– Adequate air supply for motor cooling
6.3 Reduction of Noise and Vibration
6.3.1 Primary Measures
► Operate the pump in the optimum working range.
– Do not starve the pump. Avoid throttling too much. Only
operate with a low flow rate if necessary for regulation
purposes.
– Do not operate with very high flow rates. Optionally in-
stall a flow controller in the discharge line.
– Operate the pump without cavitation (see Chapter 6.4.1,
"Installation of Pipes," page 12).
► Decouple the suction and discharge lines from vibrations.
–Support lines.
– Align lines.
– Install vibration isolators.
6.1 Safety Instructions
► Danger of injury from falling parts.
– Wear safety shoes.
– Check load capacity and attachment of hoists.
► Danger of injury from unstable assembly.
– Tighten screws to the specified tightening torque (see
Chapter 10.1.1, "Tightening Torques for Screws and Nuts,"
page 28).
– Use a torque wrench or an impact driver with adjustable
torque.
► Material damage from swinging during adjustment of
spherical cap feet.
– Use spherical cap base plates.
6.3.2 Secondary Measures
► Take structural measures such as the following:
– Acoustic paneling
– Enclosure in housing
6.4 Pump Fixation
Models FP/FPE/FP...V
► Versions A and C:
Set up the pump on the spherical cap bearings and align.
► Versions B and D:
Screw the pump on the motor foot to the foundation.
Model KF
► Versions A and C:
Set up the pump on the spherical cap bearings and align.
11
/ / FP PUMP SERIES / / /
5 - 10 x D
R ≥ 2 x D
D
► Versions B and D:
Screw the pump on the compact bearing support with base
to the foundation.
Model L
► Versions A and C:
Set up the pump on the spherical cap bearings and align.
► Versions B and D:
Screw the pump on the base frame to the foundation.
Carriage (Optional)
1. Set up the pump at the installation location. Lock the locks
on the rollers (if present) or secure the carriage with chocks.
2. Ground the carriage to dissipate electrostatic charge.
3. Position hose line to ensure that it cannot be damaged.
6.4.1 Installation of Pipes
► Lay and connect pipes as follows:
– Keep the pipe resistance as low as possible: Avoid unnec-
essary installation of valves, elbows, and abrupt pipe
transitions.
Fig. 16 Air pocket
Fig. 17 Dip in pipe
– Pipe bends upstream of suction connection: Heed mini-
mum clearance and minimum bend radius:
Fig. 18 Laying of the suction line
– Connect the pipes to the pump so that they are free of
tension and compression to ensure that no stresses are
applied to the pump.
– Secure pipes to ceilings, walls, or floor using pipe clamps.
– Align pipes flush with pump connections using a bracket.
Fig. 15 Pipe transitions
12
– Design pipe cross section so that no unnecessary pres-
sure losses or cavitation occurs in the suction area and so
that the condition
NPSHa > NPSH
r
is fulfilled.
Verify this in the project planning stage.
– Install the suction lines in horizontal position or at a con-
stant dropping angle towards the pump unit. Rule out
the possibility of air pockets and dips in the pipes.
6.5 Electrical Connection
Electrical connection may only be performed by a qualified
electrician.
1. Heed the connection values on the motor's rating plate. The
specified voltage must not be exceeded.
2. Connect the motor according to the circuit diagram in the
terminal box of the motor.
3. Protect cable feedthroughs against penetration by moisture.
4. Turn on the motor for 2 to 3 seconds. Compare the direction
of rotation of the motor fan wheel against the direction indicated by the arrow on the pump head.
5. Reverse the polarity if necessary.
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