English (GB) Installation and operating instructions
English (GB)
Original installation and operating instructions
These supplementary installation and operating
instructions apply to the ATEX-approved Grundfos
CR pumps.
The CR pumps comply with ATEX Directive 2014/34/
EU.
The pumps are suitable for use in zones classified
according to Directive 1999/92/EC. In case of doubt,
consult the above-mentioned directives, or contact
Grundfos.
1. General information
1.1 Hazard statements
The symbols and hazard statements below may
appear in Grundfos installation and operating
instructions, safety instructions and service
instructions.
CONTENTS
Page
1.General information
1.1Hazard statements
1.2Notes
2.Related installation and operating
instructions
3.Receiving the product
4.Explosion protection document
5.Identification
5.1Nameplate
5.2Type key
5.3Drive-end motor bearing
6.Scope of ATEX categories for CR
pumps
7.Installing the product
7.1Pump with single seal
7.2Pump with MAGdrive
7.3Pump with double seal
7.4Bare-shaft pumps
8.Operating conditions
8.1Maximum ambient temperature
8.2Maximum liquid temperature
8.3Temperature calculation
9.Before starting up and during operation
of an ATEX-approved pump
9.1Checklist
10.Maintenance and inspection
10.1 Tightening torques
10.2 Shaft seal
2
2
3
3
3
3
4
4
The hazard statements are structured in the
following way:
5
6
7
8
8
8
9
9
10
10
10
11
12
12
14
14
14
DANGER
Indicates a hazardous situation which, if
not avoided, will result in death or serious
personal injury.
WARNING
Indicates a hazardous situation which, if
not avoided, could result in death or
serious personal injury.
CAUTION
Indicates a hazardous situation which, if
not avoided, could result in minor or
moderate personal injury.
SIGNAL WORD
Description of hazard
Consequence of ignoring the warning.
- Action to avoid the hazard.
Read this document before installing the
product. Installation and operation must
comply with local regulations and accepted
codes of good practice.
2
Page 3
1.2 Notes
The symbols and notes below may appear in
Grundfos installation and operating instructions,
safety instructions and service instructions.
Observe these instructions for explosionproof products.
A blue or grey circle with a white graphical
symbol indicates that an action must be
taken.
A red or grey circle with a diagonal bar,
possibly with a black graphical symbol,
indicates that an action must not be taken
or must be stopped.
If these instructions are not observed, it
may result in malfunction or damage to the
equipment.
Tips and advice that make the work easier.
2. Related installation and operating
instructions
The X on the nameplate indicates that the pump is
subject to special conditions for safe use as
described in these instructions. The nameplate
markings are described in the table in section
5. Identification.
In addition to these instructions, observe the
following installation and operating instructions:
• CR, CRI, CRN: for standard pumps
• CR, CRI, CRN, CRT: removal of transport bracket
and fitting of motor. For pumps without motor
• MG: Grundfos standard motors.
For special versions of the CR pumps, observe the
relevant installation and operating instructions:
•CRN MAGdrive
• CR, CRI, CRN: double seal, back-to-back
• CR, CRI, CRN: double seal, tandem
• MG: Grundfos standard motors.
3. Receiving the product
If the pump is delivered without a motor, mount the
motor and then adjust the chamber stack and shaft
seal according to the procedure described in the
installation and operating instructions, "Removal of
transport bracket and fitting of motor", supplied with
the pump.
4. Explosion protection document
The combination of CR pump and all monitoring
equipment must be described in the explosion
protection document according to Directive 1999/92/
EC.
English (GB)
3
Page 4
5. Identification
DK-8850 Bjerringbro,Denmark
Model-PN-SN
Type
Hz
pmax/tmax
Tech file no
Made in Denmark
P code: P115482
bar/°C
min
-1
excl.motor 500kg
/hm
3
kW [P2]
H/H max m 0(,
ȘS
B-96123526-98438832
CR255-1-1A-F-A-E-HQQE
435/248
2917
64
CCW
98964685X
99356347
50/60
4.0
0.769.7
14.2/22.1
21
435-580/176
II 3G Ex h IIC T4...T3 Gb
English (GB)
5.1 Nameplate
The nameplate on the pump head gives the following
details:
• data of standard pump
• data of ATEX marking
– technical file number
– serial number
– Ex category.
Fig. 1Example of a CR nameplate with ATEX
approval
ATEX rating
Pos.Description
Group
II
I: Underground in mines
II: Surface equipment
Category
M2: Mining
3G
2G, 3G: Gas/vapours
2D, 3D: Dust
Ex hProtection type
Environment group
IIC: Gas/vapours
IIC
1
T4...T3
TM07 5039 0719
98964685
2
IIIC: Combustible dust
IIIB: Non-magnetic dust
Maximum surface
temperature according to
80079-36.
Temperature range or
specific temperature.
T4...T3: Gas
T125 °C: Dust
EPL (Equipment Protection
Level).
Gb
Gb, Gc: Gas
Db, Dc: Dust
File number for technical file
stored at DEKRA.
Indicates that the equipment
is subject to special
X
conditions for safe use. The
conditions are mentioned in
this document.
Data for the ATEX marking only refers to the part
including the coupling. The motor has a separate
nameplate.
4
Page 5
5.2 Type key
5.2.1 Type key example
ExampleCR32-21-X-X-X-X-XXXX
Type range: CR, CRN
Rated flow rate in m
Number of stages
Number of impellers with reduced diameter
Code for pump version
Code for pipe connection
Code for materials
Code for rubber pump parts
Code for shaft seal
5.2.2 Key to codes for pump version
Codes for pump version
ABasic version
BOversize motor
EPump with certificate
HHorizontal version
IDifferent pressure rating
KPump with low NPSH
MMagnetic drive
OCleaned and dried
PUndersize motor
SHigh-pressure pump
TThrust handling device (THD)
UATEX approved pump
YElectropolished
ZPumps with bearing flange
3
/h
English (GB)
5
Page 6
5.3 Drive-end motor bearing
English (GB)
Make sure to use the correct type of drive-end (DE)
motor bearing for the bare-shaft pump. Please check
the specific pump range and pump version stated on
the nameplate and select the corresponding DE
bearing.
Pump version
DE bearing
CR 1-64 pump range
1)
Deep-groove ball
bearing
(62/63xx)
Angular contact
bearing
(73xx)
Deep-groove ball
(62/63xx)
DE bearing
CR 95-255 pump range
Angular contact
bearing
bearing
(73xx)
A Standard pump0.37 - 3 kW4-45 kW75-200 kW5.5 - 55 kW
Pump with thrust
T
handling device
2)
(THD)
Pump with bearing
Z
1)
2)
2)
flange
Refer to the codes for pump version in section 5.2 Type key.
Factory product variants (FPV).
--5.5 - 55 kWNot allowed
0.37 - 45 kWNot allowed5.5 - 200 kWNot allowed
6
Page 7
6. Scope of ATEX categories for CR pumps
DirectiveATEX-approved CR pumps
2014/34/EUGROUP I
Category M
Environment:
EPL1):MaMb
1999/92/EC
2)
CR pumpsNone
MotorsNoneNone
2014/34/EUGROUP II
Category 1Category 2Category 3
Environment:
1)
EPL
:GaDaGbDbGcDc
1999/92/EC
2)
GDGDGD
Zone 0 Zone 20Zone 1Zone 21Zone 2Zone 22
CR pumpsNoneNone
MotorsNoneNone
1)
EPL: Equipment Protection Level.
2)
Important: The link between groups, categories
and zones is explained in Directive1999/92/EC.
Note that this is a minimum directive. Some EU
countries may therefore have stricter local rules.
The user or installer is always responsible for
checking that the group and category of the
pump correspond to the zone classification of the
installation site.
12
-CR
CRI
CRN
CR
CRI
CRN
CRT
• II 2G Ex eb
IIC T3 Gb
• II 2G Ex db
IIC T4 Gb
CR
CRI
CRN
CRT
• II 2D Ex tb
IIIC T125 °C
Db
CR
CRI
CRN
CRT
• II 2G Ex eb
IIC T3 Gb
• II 2G Ex db
IIC T4 Gb
CR
CRI
CRN
CRT
• II 3D Ex tc
IIIC T125 °C
Dc
English (GB)
7
Page 8
7. Installing the product
English (GB)
DANGER
Explosion risk
Death or serious personal injury
- Do not let the pump run dry.
- Make sure that the pump is filled with
pumped liquid during operation.
DANGER
Explosion risk
Death or serious personal injury
- Replace the shaft seal if increased
leakage is observed.
DANGER
Explosion risk
Death or serious personal injury
- Always install the pump with the motor
above the pump to avoid overheating of
the motor bearings. See fig. 2.
The responsibility for checking the
functions of the dry-running protection,
such as flow rate, sealing pressure and
temperature of the barrier or flushing
liquid, rests with the installer or owner.
Fig. 2Positioning the pump
7.1 Pump with single seal
7.1.1 Non-flammable liquids
Category 2G/D/M2
Make sure that the pump is filled with pumped liquid
during operation. If this is not possible, ensure
appropriate monitoring, for example dry-running
protection to stop the pump in case of malfunction.
Category 3G/D
No additional monitoring, for example dry-running
protection, is required for the pump system.
7.1.2 Flammable liquids, pump unit
Category 2G/D/M2 and 3G/D/M2
Make sure that the pump is filled with pumped liquid
during operation. If this is not possible, ensure
appropriate monitoring, for example dry-running
protection to stop the pump in case of malfunction.
Ensure sufficient ventilation around the pump.
The leakage rate of a shaft seal is 1-10 ml for each
24 hours of operation. For some types of liquids, the
leakage will not be visible due to evaporation. During
the run-in period, larger leakage of 1-20 ml per 24
hours of operation can occur. Liquids like oil or
glycol-water mixtures evaporate slower than water
and will leave residuals. Ensure proper ventilation to
maintain the zone classification.
Category M2
Protect the pump with a guard to prevent damage
from falling or ejected objects.
7.2 Pump with MAGdrive
DANGER
TM01 1241 4102
See the CRN MAGdrive installation and operating
instructions at http://net.grundfos.com/qr/i/
96464310.
Explosion risk
Death or serious personal injury
- Always fill the pump with liquid and
ensure that the required minimum flow
rate is obtained.
8
Page 9
7.3 Pump with double seal
40 50 60 70 80 90 100 110 120
t [°C]
0
10
20
30
Qmin
[%]
Back-to-back or tandem
7.3.1 Non-flammable liquids, pump unit
Category 2G/D
Make sure that the pump is filled with pumped liquid
during operation. If this is not possible, ensure
appropriate monitoring, for example dry-running
protection to stop the pump in case of malfunction.
Category 3G/D
No additional monitoring, such as dry-running
protection, is required for the pump system.
7.3.2 Flammable liquids, pump unit
Category 2G/D/M2 and 3G/D/M2
Make sure that the pump is filled with pumped liquid
during operation. If this is not possible, ensure
appropriate monitoring, for example dry-running
protection to stop the pump in case of malfunction.
Ensure sufficient ventilation around the pump.
The leakage rate of a shaft seal is 1-10 ml for each
24 hours of operation. For some types of liquids, the
leakage will not be visible due to evaporation. During
the run-in period, larger leakage of 1-20 ml per 24
hours of operation can occur. Liquids like oil or
glycol-water mixtures evaporate slower than water
and will leave residuals. Ensure proper ventilation to
maintain the zone classification.
Category M2
Protect the pump by a guard to prevent damage from
falling or ejected objects.
7.4 Bare-shaft pumps
Bare-shaft pumps with motors of 4 kW and up must
use angular contact bearings.
However, if the pumps are fitted with a thrust
handling device (THD) or a bearing flange, they must
never be used with angular contact bearings. If in
doubt, contact Grundfos.
Check if the pump is fitted with a thrust
handling device (THD). If the pump is a
THD marked pump, follow the instructions
below.
The thrust handling device (THD) is factory-fitted on
CR, CRN 95-255 for motor sizes of 75 kW and
above.
7.4.1 Bare-shaft pumps with a thrust handling
device
DANGER
Explosion risk
Death or serious personal injury
- Temperature monitoring of the motor
bearings is required to ensure that the
pump stops in case of overheating.
DANGER
Explosion risk
Death or serious personal injury
- Do not use ATEX motors with angular
contact bearings on pumps fitted with a
thrust handling device (THD).
DANGER
Explosion risk
Death or serious personal injury
- Temperature sensors must be installed
by qualified persons in accordance with
local regulations.
Minimum flow rate
Due to the risk of overheating, do not use the pump
at flows below the minimum flow rate.
The curve below shows the minimum flow rate as a
percentage of the rated flow rate in relation to the
liquid temperature.
Fig. 3Minimum flow rate in percentage of
nominal flow
English (GB)
TM02 8290 4903
9
Page 10
8. Operating conditions
English (GB)
DANGER
Explosion risk
Death or serious personal injury
- Ensure that the required minimum inlet
pressure is always available.
See the CR, CRI, CRN installation and operating
instructions:
- Do not operate the pump with higher
liquid temperature than the maximum
liquid temperature (t
pump nameplate.
- The calculated maximum permissible
liquid temperature must not be
exceeded.
) stated on the
max
8.1 Maximum ambient temperature
The maximum ambient temperature for the pump: 20 to +60 °C.
8.2 Maximum liquid temperature
In normal pump operation, the highest temperatures
are to be expected at the surface of the pump casing
and at the shaft seal. The surface temperature will
normally follow the temperature of the liquid.
You can calculate the permissible liquid temperature
by finding the maximum permissible temperature at
the surface of the pump during operation in the table
shown in section 8.3.1 Temperature class, and
reduce it with the temperature contribution from shaft
seals, see table in section 8.3.2 Shaft seal
temperature.
Section 8.3 Temperature calculation contains a
diagram which shows how the maximum surface
temperature depends on the liquid temperature and
the temperature contribution from the shaft seal.
Calculation example
Based on temperature contribution from a HQQX
shaft seal, media class 1, shaft diameter ∅22 and
pressure 2.5 Mpa.
Temperature class (T4) = 135 °C, see section
8.3.1 Temperature class.
Temperature contribution from HQQX shaft seal = 24
°C, see section 8.3.2 Shaft seal temperature.
Safety margin for Group II = 5 °C according to the
ATEX standard.
Result
Maximum permissible liquid temperature:
T4-contribution from shaft seal-safety margin = 135 -
24 - 5 = 106 °C.
Pumps that are allowed to pump liquids up to a
maximum of 150 °C are equipped with a tandem
shaft seal. In this case, the temperature and flow rate
of the flushing liquid must be according to the
description in the installation and operating
instructions "CR, CRI, CRN-Double seal (tandem)" at
http://net.grundfos.com/qr/i/96477555.
Make sure that the combination of CR pump and dryrunning protection is described in the explosion
protection document according to Directive 1999/92/
EC.
The responsibility for checking the correct
flow rate and the temperature of the
flushing liquid rests with the installer or
owner.
Increased leakage rate can indicate
damaged elastomers and rubber parts in
the pump. For some liquid types, the
leakage is not visible due to evaporation.
10
Page 11
8.3 Temperature calculation
1
2
3
The illustration below shows the maximum surface
temperature of the pump as a result of the maximum
liquid temperature and temperature rise in the shaft
seal.
Fig. 4Maximum surface temperature
Pos.Figure legend
Maximum surface temperature of the
1
pump
Temperature rise in the shaft seal.
2
Calculated by Grundfos. See section
8.3.2 Shaft seal temperature.
3Maximum liquid temperature
8.3.1 Temperature class
Temperature class
T1450
T2300
T3200
T4135
T5100
T685
The maximum surface temperature for dust is stated
on the nameplate.
Maximum surface
temperature
[°C]
8.3.2 Shaft seal temperature
In order to calculate the pump surface temperature
and temperature class, the below tables show the
temperature rise in the shaft seal for different shaft
diameters, different pressure values and various
media classes.
Shaft seal: HQQx/HUUx/HQUx and
AUUx/AQQx/DQQx
Rpm: 2900/3500
Pressure [MPa]
12.54
Shaft seal temperature rise [°C]
222426
Rpm: 2900/3500
Pressure [MPa]
12.54
Shaft seal temperature rise [°C]
182022
TM06 4445 2315
Shaft
diameter
[mm]
12
16
22
28
36
Shaft
diameter
[mm]
12
16
22
28
36
Shaft seal: HQBx/HUBx
English (GB)
11
Page 12
9. Before starting up and during
English (GB)
operation of an ATEX-approved
pump
DANGER
Explosion risk
Death or serious personal injury
- Do not run the pump at speeds
exceeding the rated speed. See pump
nameplate.
9.1 Checklist
DANGER
Explosion risk
Death or serious personal injury
- Follow the checklist below.
Observe this checklist:
1. Check that the ATEX rating of the motor, pump
and accessories corresponds to the specified
category. See section 6. Scope of ATEX
categories for CR pumps. If the motor, pump or
accessory categories differ, the lower rating is
valid.
2. If the pump falls under category M2, check that
the pump is protected by a guard to prevent
damage from falling or ejected objects.
3. Clean the cavities behind the pump's coupling
guard on a regular basis to avoid hazardous dust
deposits.
4. Check that the motor output power corresponds
to the required P
5. Check that the pump is as ordered, see
nameplates.
6. Check the axial alignment of the chamber stack.
See the label on the inside of the coupling guard.
Check that the shaft seal components, rubber
parts and seal surfaces are suitable for the
pumped liquid.
7. Check that the shaft can rotate freely. There must
be no mechanical contact between impeller and
chamber.
8. Check that the pump has been filled with liquid
and vented. The pump must never run dry.
9. Check the direction of rotation of the motor, see
the arrow on the top of the fan cover.
10. If you have chosen a pump with double seal,
back-to-back, check that the seal chamber is
pressurised. Always pressurise the chamber
during operation. Always use ATEX-approved
equipment.
of the pump, see nameplates.
2
11. If you have chosen a pump with double seal,
tandem, check that the seal chamber is
completely filled with liquid. The seal chamber
must always be filled with flushing liquid during
operation. The dry-running protection must be
ATEX-approved.
12. Follow the special startup procedures for these
pump types:
– MAGdrive pumps
– pumps with double seal, back-to-back
– pumps with double seal, tandem.
For further information, see the installation and
operating instructions for the pump in question.
13. Check that the liquid temperature never exceeds
the maximum liquid temperature, t
the nameplate.
14. Avoid overheating of the pump.
Operation against a closed outlet valve may
cause overheating. Install a bypass with a
pressure relief non-return valve.
15. Check for abnormal noise during operation to
avoid overheating of the pump.
16. Re-vent the pump in either of these situations:
– the pump has been stopped for a period of
time.
– air has accumulated in the pump.
17. If the pump is with bearing bracket, check for
bearing noise every week. Replace the bearing if
it shows signs of wear.
18. The auto-ignition temperature of the pumped
liquid must be 50 K above the maximum surface
temperature of the pump.
19. Make sure to apply the correct inlet pressure.
Use the correct table for the vapour pressure for
the pumped liquid. See section
9.1.1 Specification and calculation of inlet
pressure.
, stated on
max
12
Page 13
9.1.1 Specification and calculation of inlet
Hv
H
NPSH
Pb
Hf
20
15
12
10
8,0
6,0
5,0
4,0
3,0
2,0
1,0
0,8
0,6
0,4
0,3
0,2
0,1
1,5
120
110
90
100
80
70
60
50
40
30
20
10
0
Hv
(m)
tm
(°C)
150
130
140
25
35
45
40
30
160
170
180
190
62
79
100
126
pressure
Fig. 5Schematic view of open system with a
CR pump
Calculation of inlet pressure
Calculate the maximum suction lift "H" in m head as
follows:
H= Pb x 10.2 - NPSH - Hf - Hv - Hs
English (GB)
TM02 0118 3800
Pb= Barometric pressure in bar.
Barometric pressure can be set to 1 bar.
In closed systems, Pb indicates the
system pressure in bar.
be read from the NPSH curve in the
appendix* (at the highest flow rate the
pump will be delivering).
* Link to appendix, see section
Appendix with NPSH curves.
at the highest flow rate the pump will be
delivering.
See fig. 6. If the pumped liquid is not
water, then use the vapour pressure for
the liquid which is being pumped.
Fig. 6Vapour pressure for water in m head
If the calculated "H" is positive, the pump can
operate at a suction lift of maximum "H" m head.
If the calculated "H" is negative, an inlet pressure of
minimum "H" m head is required. There must be a
pressure equal to the calculated "H" during
operation.
Example:
Pb = 1 bar.
Pump type: CR 15, 50 Hz.
Flow rate: 15 m
3
/h.
NPSH (see the appendix*): 1.1 m head.
Hf = 3.0 m head.
Liquid temperature: 60 °C.
Hv (see fig. 6): 2.1 m head.
H = Pb x 10.2 - NPSH - Hf - Hv - Hs [m head].
H = 1 x 10.2 - 1.1 - 3.0 - 2.1 - 0.5 = 3.5 m head.
This means that the pump can operate at a suction
lift of maximum 3.5 m head.
Pressure calculated in bar: 3.5 x 0.0981 = 0.343 bar.
Pressure calculated in kPa: 3.5 x 9.81 = 34.3 kPa.
* Link to appendix, see section Appendix with
NPSH curves.
TM02 7445 3503
13
Page 14
9.1.2 Appendix with NPSH curves
Coupling screw
(4 pcs)
Shaft seal
Shaft seal set screw
(3 pcs)
Shaft seal set screw (3 pcs)
Shaft seal flange screw (4 pcs)
English (GB)
Appendix:
The appendix referred to in section 9.1.1 is
found in the standard CR, CRI, CRN
installation and operating instructions:
http://net.grundfos.com/qr/i/96462123
10. Maintenance and inspection
Service documentation is available in Grundfos
Product Center (http://productselection.grundfos.com/).
If you have any questions, please contact the
nearest Grundfos company or service workshop.
10.1 Tightening torques
DANGER
Explosion risk
Death or serious personal injury
- The coupling screws, shaft seal, shaft
seal flange screws and shaft seal set
screws must be tightened according to
the specified torque values.
Bombas GRUNDFOS de Argentina S.A.
Ruta Panamericana km. 37.500 Centro
Industrial Garin
1619 Garín Pcia. de B.A.
Phone: +54-3327 414 444
Telefax: +54-3327 45 3190
Australia
GRUNDFOS Pumps Pty. Ltd.
P.O. Box 2040
Regency Park
South Australia 5942
Phone: +61-8-8461-4611
Telefax: +61-8-8340 0155
GRUNDFOS Sarajevo
Zmaja od Bosne 7-7A,
BH-71000 Sarajevo
Phone: +387 33 592 480
Telefax: +387 33 590 465
www.ba.grundfos.com
e-mail: grundfos@bih.net.ba
Brazil
BOMBAS GRUNDFOS DO BRASIL
Av. Humberto de Alencar Castelo
Branco, 630
CEP 09850 - 300
São Bernardo do Campo - SP
Phone: +55-11 4393 5533
Telefax: +55-11 4343 5015
Bulgaria
Grundfos Bulgaria EOOD
Slatina District
Iztochna Tangenta street no. 100
BG - 1592 Sofia
Tel. +359 2 49 22 200
Fax. +359 2 49 22 201
email: bulgaria@grundfos.bg
Grundfos Pompe România SRL
S-PARK BUSINESS CENTER, Clădirea
A2, etaj 2, Str. Tipografilor, Nr. 11-15,
Sector 1, Cod 013714, Bucuresti,
Romania,
Tel: 004 021 2004 100
E-mail: romania@grundfos.ro
www.grundfos.ro
Russia
ООО Грундфос Россия
ул. Школьная, 39-41
Москва, RU-109544, Russia
Тел. (+7) 495 564-88-00 (495) 737-3000
Факс (+7) 495 564 8811
E-mail grundfos.moscow@grundfos.com
Serbia
Grundfos Srbija d.o.o.
Omladinskih brigada 90b
11070 Novi Beograd
Phone: +381 11 2258 740
Telefax: +381 11 2281 769
www.rs.grundfos.com