ITT ICB Installation, Operation And Maintenance Instructions

Download

Page 1

Goulds Pumps

Artikel Nr. 771076102 Rev. 02 01/2010

Goulds-Volute Casing Pumps Model: ICB

Installation, Operation and Maintenance Instruction

Translation of the Original Operation Manual

Keep for further use !

Pay attention to this operating instruction before the delivery, installation, start-up a.s.o.!

Page 2

Page 3

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 1

Revision 02

Article No 771076102

Issue 01/2010

TABLE of CONTENTS

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

ATEX-Label (only for pumps in compliance with

EC directive 94/9/EG)................................................ 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

3.1.1 Design Coding System................................... 6

3.2 Shaft Sealing..................................................... 7

3.3 Bearing.............................................................. 7

3.4 Approximate Value for Sound Pressure Level .. 7

3.5 Permitted Nozzle Loads and Torques at the

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

3.6 Permitted pressures and temperatures............. 8

3.7 Condensate....................................................... 9

4. Transport, Handling, Storage .............................. 9

4.1 Transport, Handling........................................... 9

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 Drive................................................................ 10

5.4 Electric Connection ......................................... 10

5.5 Final Control.................................................... 11

6. Start-up, Operation, Shut down ........................ 11

6.1 Initial start-up................................................... 11

6.2 Switch on drive................................................ 11

6.3 Restarting ........................................................11

6.4 Limits of Operation ..........................................11

6.5 Lubrication .......................................................12

6.6 Monitoring........................................................12

6.7 Shutting down..................................................12

6.8 Storage / longer periods of non-operation ....... 12

7. Servicing, Maintenance ......................................13

7.1 General remarks..............................................13

7.2 Mechanical seals .............................................13

7.3 Motor bearings.................................................13

7.4 Cleaning of pump ............................................13

8. Dismantling and repair of pump ........................13

8.1 General remarks..............................................13

8.2 General............................................................13

8.3 Removal and Installation of screen in the motor

lantern....................................................................13

8.4 Removal of the Back Pull Out Assembly ......... 14

8.5 Removal of Impeller.........................................14

8.6 Removal of Shaft Sealing ................................14

8.7 Removal of Stub Shaft.....................................14

8.8 Reconditioning.................................................15

8.9 Mounting..........................................................15

9. Spare parts, Spare pumps..................................16

9.1 Spare parts ......................................................16

9.2 Stand-by pumps...............................................16

10. Faults - Causes and Solutions.........................17

11. Motor Operating Instructions ..........................18

Installation Manual - Single mech. seal without shaft

sleeve (Design code S1..2) .......................................20

Installation Manual - Single mech. seal with quench

without shaft sleeve (Design code S4..2) ………...... 22

Sectional drawing pump unit (Design code S1..2),

Impeller with back vanes.......................................... 25

Sectional drawing pump unit (Design code S1..2),

Impeller with balancing holes ................................... 26

Sectional drawing pump unit (Design code S4..2),

Impeller with back vanes.......................................... 27

Sectional drawing pump unit (Design code S4..2),

Impeller with balancing holes ................................... 28

Connections ............................................................. 29

Dimensional drawing................................................ 30

Page 4

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 2

Revision 02

Article No 771076102

Issue 01/2010

Pump Name Plate

Type *) Type 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

all w C

Max. permitted casing-operation-pressure

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

max op

Maximum permitted operating temperature of

pumped liquid Item No Customer related order number Imp∅ Outer diameter of the impeller

*) 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.

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

CE Marking of compliance with the EC directive

94/9/EG Ex specific marking for explosion protection II Symbol for the appliance group 2G Symbol for the category (2), explosive

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

(constructual 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

temperature of pumped liquid refer to pump

name plate, data sheet and / or order

confirmation.

The conformity with the EC directive 94/9/EG "Appliances and Protection Systems for designated use in areas endangered to explosion" is declared by the issue of the EC-Declaration of Conformity and the attachment of the ATEX-label at the pump (adapter). The ATEX-label is attached additionally to the pump name plate.

Page 5

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 3

Revision 02

Article No 771076102

Issue 01/2010

1. General

This product corresponds with the requirements of the Machine directive 2006/42/EG.

The staff employed on installation, operation,

inspection and maintenance must be able to

prove that they know about the relevant

accident preven

tion 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.

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!

Page 6

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 4

Revision 02

Article No 771076102

Issue 01/2010

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

property 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

machine 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.

 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.

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 having 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 itself

must permanently be filled with the pumped

liquid.

Thus, no explosive atmosphere can develop

and the danger of dry-run is avoided.

Page 7

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 5

Revision 02

Article No 771076102

Issue 01/2010

If the operator can´t guarantee that, according

monitoring measures must be provided.

Equally all seal casings, auxiliary systems of 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 the motor resp. further addi

tions 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 T1-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, motor) with different temperature classes the lowest is valid.

2.7.3 Rotation Control

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 of

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 th

e pump

casing after 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.

On pumps with mech. seals the perm

itted

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. In the area of lantern and motor free contact of surface to environment must be given for proper cooling.

During operation of the pump it must be

secu

red that an overabundant sedimentation of

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 class acc.

EN 13463-1 T4 (135°C) 135°C T3 (200°C) 140°C T2 (300°C) 140°C T1 (450°C) 140°C

The particular allowed operating temperature of

the pump is shown in the data sheet and / or the

order confirmation resp. the type plate at the

pump.

2.7.6 Maintenance

For a secure and reliable operat

ion it must be

secured by regular inspections, that the unit is

maintained competently and is kept in good

technical condition.

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 installed, it must be checked, if monitoring devices are necessary to secure the function.

Page 8

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 6

Revision 02

Article No 771076102

Issue 01/2010

2.7.7 Electric switches and control device, Instrumentation and accessories

Electri

c switches and control devices,

instru

mentation and accessories 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, 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

Basically the suction and discharge piping must

be designed in such way, that as little forces as

possible are effective to the pump. If tha

t 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

pos

sible 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

ICB-pumps are single-stage volute casing pumps in

block design. Hydraulic design and dimensions comply with ISO 2858/ EN 22858, the technical design complies with ISO 5199/EN 25199. The motors comply with DIN 42677-IM B5. Motor and pump shaft are coupled rigidly. The permitted application conditions and design details of the delivered pump are shown in the attached data sheet and / or the order confirmation (see Design Coding System in chapter 3.2).

Installation position: ICB-pump are intended for use with horizontal shaft, discharge up. Installation positions deviating therefrom must be approved by the manufacturer.

3.1.1 Design Coding System

Due to the coding on data sheet and / or order confirmation all information regarding the delivered

pump can be found in this Installation, Operation and Maintenance Instruction, e.g.: ICB 100 - 65 - 250 S1 V L 2 - 132 (0) (1) (2) (3) (4)

(5) (6) (7) (8)

Position (0) - Name of Model ICB - ISO block pump

Position (1) - Suction Nozzle in mm Position (2) - Discharge Nozzle in mm Position (3) - Nominal diameter of impeller in mm Position (4) - Shaft sealing

S1 - Single-mech. seal acc. DIN 24960 l1k / EN 12756 form U S4 - Single-mech. seal acc. DIN 24960 l1k / EN 12756 form U with Quench (throttle bush)

Position (5) - Material Impeller N = Cast Iron (0.6025) L = Ductile Iron (0.7043) V = Carbon Steel (1.4408) W = Duplex (1.4517)

Page 9

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 7

Revision 02

Article No 771076102

Issue 01/2010

Position (6) - Material pump casing (same coding as impeller, cast iron not available)

Position (7) - Stub shaft

2 - without shaft sleeve (Duplex 1.4462 std)

Position (8) - IEC Motor size

3.2 Shaft Sealing

Pumps of design ICB are exclusively sealed with single mech. seals with installation dimensions acc. to EN 12756 (DIN 24960), design "K", form "U". Two shaft sealing variants are available. On the data sheet and / or the order confirmation the kind of shaft sealing is given. An instruction for the mounting and operation of mech. seals is contained in the particular "Mounting Instruction of Shaft Sealing". For nominal size (d1) of the mech. seal refer to following chart.

Type

nom. size

d1 of mech.

seal

Type

nom. size

d1 of mech.

seal

40-25-160 33

100-65-160 43

40-25-200 33

100-65-200 43

40-25-250 43

100-65-250 43

50-32-160 33

100-65-315 53

50-32-200 33

125-80-160 43

50-32-250 43

125-80-200 43

50-32-315 43

125-80-250 43

65-40-160 33

125-80-315 53

65-40-200 33

125-100-200 43

65-40-250 43

125-100-250 53

65-40-315 43

125-100-315 53

80-50-160 33

150-125-250 53

80-50-200 33

150-125-315 53

80-50-250 43

200-150-250 53

80-50-315 43

The

mech. seal used in the standard design is

not resistant to mineral oils.

For further details about mech. seals, as well as

the dangers of accidents, connected to them

refer to chapter 6.6 and chapter 7.2.

3.3 Bearing

The shaft is guided by the ball bearings of the motor. The bearings are grease lubricated for life and, therefore maintenance-free.

3.4 Approximate Value for Sound Pressure Level

Sound pressure level LpA in dB(A)

Pump alone Pump + Motor

Nominal power PN in kW

2950 min-1

1450 min-1

975

min-1

2950 min-1

1450 min-1

975

min-1 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 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 - 75,0 72,0 37,0 73,0 - - 76,0 - -

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. All values for forces and torques refer to standard materials EN-GJS400-18LT and 1.4408.

pic 1

Page 10

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 8

Revision 02

Article No 771076102

Issue 01/2010

Suction nozzle Discharge nozzle

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

∅DN

Fx Fy Fz

∑F

Mx My Mz

∑M

∅DN

Fx Fy Fz

∑F

Mx My Mz

∑M 40-25-160 40 700 620 560 1100 730 500 590 1070 25 420 400 480 730 500 340 400 730 40-25-200 40 700 620 560 1100 730 500 590 1070 25 420 400 480 730 500 340 400 730 40-25-250 40 700 620 560 1100 730 500 590 1070 25 420 400 480 730 500 340 400 730 50-32-160 50 920 840 760 1450 780 560 650 1150 32 500 480 590 930 620 420 480 900 50-32-200 50 920 840 760 1450 780 560 650 1150 32 500 480 590 930 620 420 480 900 50-32-250 50 920 840 760 1450 780 560 650 1150 32 500 480 590 930 620 420 480 900 50-32-315 50 920 840 760 1450 780 560 650 1150 32 500 480 590 930 620 420 480 900 65-40-160 65 1180 1040 950 1850 840 620 670 1230 40 620 560 700 1100 730 500 590 1060 65-40-200 65 1180 1040 950 1850 840 620 670 1230 40 620 560 700 1100 730 500 590 1060 65-40-250 65 1180 1040 950 1850 840 620 670 1230 40 620 560 700 1100 730 500 590 1060 65-40-315 65 1180 1040 950 1850 840 620 670 1230 40 620 560 700 1100 730 500 590 1060 80-50-160 80 1400 1260 1150 2200 900 650 730 1320 50 840 760 920 1450 780 560 650 1150 80-50-200 80 1400 1260 1150 2200 900 650 730 1320 50 840 760 920 1450 780 560 650 1150 80-50-250 80 1400 1260 1150 2200 900 650 730 1320 50 840 760 920 1450 780 560 650 1150 80-50-315 80 1400 1260 1150 2200 900 650 730 1320 50 840 760 920 1450 780 560 650 1150

100-65-160 100 1880 1680 1520 2950 980 700 810 1450 65 1040 950 1180 1850 840 620 670 1230 100-65-200 100 1880 1680 1520 2950 980 700 810 1450 65 1040 950 1180 1850 840 620 670 1230 100-65-250 100 1880 1680 1520 2950 980 700 810 1450 65 1040 950 1180 1850 840 620 670 1230 100-65-315 100 1880 1680 1520 2950 980 700 810 1450 65 1040 950 1180 1850 840 620 670 1230 125-80-160 125 2210 2000 1800 3480 1180 840 1070 1710 80 1260 1150 1400 2200 900 650 730 1320 125-80-200 125 2210 2000 1800 3480 1180 840 1070 1710 80 1260 1150 1400 2200 900 650 730 1320 125-80-250 125 2210 2000 1800 3480 1180 840 1070 1710 80 1260 1150 1400 2200 900 650 730 1320

125-80-315 125 2210 2000 1800 3480 1180 840 1070 1710 80 1260 1150 1400 2200 900 650 730 1320 125-100-200 125 2210 2000 1800 3480 1180 840 1070 1710 100 1680 1520 1880 2950 980 700 810 1450 125-100-250 125 2210 2000 1800 3480 1180 840 1070 1710 100 1680 1520 1880 2950 980 700 810 1450 125-100-315 125 2210 2000 1800 3480 1180 840 1070 1710 100 1680 1520 1880 2950 980 700 810 1450 150-125-250 150 2800 2520 2270 4400 1400 980 1150 2050 125 2000 1800 2210 3480 1180 840 1070 1710 150-125-315 150 2800 2520 2270 4400 1400 980 1150 2050 125 2000 1800 2210 3480 1180 840 1070 1710 200-150-250 200 3750 3360 3030 5850 1820 1290 1490 2700 150 2520 2270 2800 4400 1400 980 1150 2050

3.6 Permitted pressures and temperatures

Basically the values, regarding pressures and temperatures, given in the data sheet and / or the order confirmation, as well as on the name plate. Exceeding or remaining under of these values are undue. If there are no pressures and / or temperatures mentioned in data sheet and / or order confirmation,

the following limits are valid for suction pressure and room temperature:

Suction pressure (System pressure) = Pressure at pump suction: max. 5 bar Ambient temperature max. 40°C.

On Application of pumps local laws and regulations must be noticed, as well (e.g. DIN 4747 or DIN 4752, section 4.5).

For all pump types, except:

50-32-315 - 65-40-315 - 80-50-315 - 100-65-315 125-80-315 - 125-100-315

Only for:

50-32-315 - 65-40-315 - 80-50-315 - 100-65-315 125-80-315 - 125-100-315

Curve Casing material Description

A 1.4408 Austenitic Steel B 1.4517 Duplex Steel

EN-GJS-400-18-LT

(0.7043)

Ductile Iron

The given pressure and temperature limits are valid for standard mech. seals. Application limits for other materials on request.

Page 11

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 9

Revision 02

Article No 771076102

Issue 01/2010

3.7 Condensate

On motors which are subject to strong temperature deviations or extreme climatic conditions, we recommend the use of a motor with stand-by heating

to avoid formation of condensate inside the motor. The stand-by heating must not be switched on during the operation of the motor.

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

carefully 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 authorized persons.

 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.

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 / unit of the transport

lifting device can cause damages to persons

and things.

pic 2

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. Mounting / Installation

5.1 Mounting of Pump / Unit

The pumps must be bolted to a solid base (e.g. concrete foundation, steel plate, steel bracket, etc.). This base must withstand all loads occurring during operation. 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 erected. Its surface must be horizontal and even. For the position and size of the pump feet and the foundation screws refer to the dimensional drawing.

Concrete expansion bolts, epoxy capsule anchor bolts or anchor bolts grouted with the foundation (stone screws), can be used for.

Sufficient space must be provided for

mainte

nance and repair work, especially for

replacing the drive motor or the com

plete 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.

 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. Levelling shims

Page 12

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 10

Revision 02

Article No 771076102

Issue 01/2010

must be inserted next to the foundation anchors and must lie plainly.

 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

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

The size of these insulating pads will

vary,

pending on circumstances, and should

there

fore be determined by an experienced

specialist.

5.2 Connection of Pipings to the Pump

The pump must not be used as fixed point for

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. Do not install fittings or elbows right before the suction nozzle.

 If the suction supply is under vacuum and

entrained gas may be present in the liquid, it is recommended that a vent line (min. diameter 25 mm) 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

3.7).

 If expansion joints are used in the pipes, they

have to be supported in such a way that the pump is not loaded unduly 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 mechanical

seals) against foreign impurities, it is recommended 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

installed, 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).

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 Drive

Note the Operating Instructions of the motor manufacturer.

On application in zone 1 and 2 a motor with

valid Atex-certification must be used.

If in the process of the repair a new motor is used , the following has to be noticed:  The motor must comply with the requirements

stated in sheet 1220.1A608 (order from manufacturer, on demand).

 Clean motor end and motor flange of new motor

carefully (remove varnish).

5.4 Electric Connection

Elec

trical connection work may only be carried

out by an authorised professional. The rules

and regulations valid for electrical technology,

especially those concerned with safety

meas

ures, must be observed. The regulations

of the national power supply compani

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

Page 13

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 11

Revision 02

Article No 771076102

Issue 01/2010

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 60079-

must additionally be noticed for the electric

installation.

The direction of rotation must only be checked

when the pump is full. Dry running will cause

damage to the pump.

5.5 Final Control

It must be possible to turn the unit easily by hand at the stub shaft.

6. Start-up, Operation, Shut down

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:  There´s no need to lubricate the pump before

starting it 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 lantern guard sheets are mounted and

that all safety devices are operational.

 Switch on any existing sealing or flushing pipings.

For quantities and pressures refer to data sheet and / or order confirmation.

 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 drive lantern.

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 clos

ed valve in the suction and /

or discharge piping is not permitted.

On starting-up without back-pressure, the back-

pressure must be produced through throttling at

the discharge side. After reaching full backpressure open valve.

If pump does no

t reach attended head or if

atypical sounds or vibrations do occur:

Switch off pump (see chapter 6.7) and seek for

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 ho

t machine

parts and when working in the unprotected shaft

seal area. Remember that automatically

con

trolled 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

con

firmation and must be observed under any

circumstances!

 Do not exceed the output given on the motor

name plate.

 Avoid sudden changes in temperature

(temperature shocks).

 The pump and motor should run evenly and

without 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:

min

= 0,1 x Q

BEP

for for short time operation

min

= 0,3 x Q

BEP

for continuous operation

max

= 1,2 x Q

BEP

for continuous operation *)

BEP

= Flow in efficiency optimum

*) on condition that NPSH

facility

> (NPSH

pump

+ 0,5 m)

Page 14

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 12

Revision 02

Article No 771076102

Issue 01/2010

6.4.2 Abrasive Media

On pumping liquids with ab

rasive components

an increased wear at hydraulic and shaft sea

ling

must be expected. The intervals of inspec

tion

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.

1,0

10,0

100,0

1 10 100 1000

Motor power [kW]

max. perm. starts/h

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

The pump has no bearings and, therefore there´s no need for lubrication. For possibly required lubrication of the motor bearings refer to the Operation and Maintenance Instructions of the motor supplier.

6.6 Monitoring

In areas endang

ered to explosion it is

recom

mended to monitor the temperature of the

bearings and the vibrations of the pump.

Regular monitoring and maintenance will ex

tend

the life of your pump or pump system.

 Check pump for leaks at least once a week.  Check the regulating and monitoring devices of

any sealing or flushing systems once a week to ensure that they function properly. Outgoing cooling water should be handwarm.

 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. 10 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 circuit.  On danger of freezing empty pump and pipes

completely.

 If pump remains under pressure and temperature

when stationary: leave existing sealing and flushing 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

Start-up must be handled like initial start-up (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 under pressure and

temperature: leave all existing sealing and flushing systems swiched on.

 Replace motor bearings after 5 years.

b) Drained pumps

 Turn shaft at least 1x week (do not switch on

because of dry running).

 Replace motor bearings after 5 years.

Page 15

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 13

Revision 02

Article No 771076102

Issue 01/2010

7. Servicing, Maintenance

7.1 General remarks

Work should only be carried out on the pump or

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 p

ump, 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 Motor bearings

After approx. 5 years the grease in the motor bearings is so aged, that a replacement of the bearings is recommended. However, the bearings must be replaced after 25000 operating hours, at least, resp. acc. to the Maintenance Instruction of the motor supplier, if that recommends a shorter maintenance period.

7.4 Cleaning of pump

 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).

The pump must not be cleaned with pressuri

sed

water - water will get into the bearings.

8. Dismantling and repair of pump

8.1 General remarks

Repair to the pump or pump system may only

be carried out by authorised s

killed 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 approp

riate

disposal of the handled liquid is necessary

befo

re the disassembly of the pump. Pay

attention to the fact, that even in drained pumps

there are remainders of the handled liquid. If

necessary the pump must be flushed or

decontaminated. Laws must be ob

served,

otherwise danger to health is existing!

 Before the disassembly the pump has to be

secured 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 n

danger of setting fire, cause an explosion or

cause injurious vapours.

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 Removal and Installation of screen in the motor lantern

The guard plates (680) are fixed in the windows of the motor lantern (681). For removing insert a screwdriver about 4 cm into the last row with punches of the guard plate. Then pull up the screwdriver until the lower edge of the guard plate lifts off the window. Now you can remove the screwdriver together with the guard plate from the window (see picture 8).

On installation insert the screwdriver about 4 cm into the last row with punches of the guard plate. Then put the upper part of the guard plate into the upper edge of the window. Now pull up the screw driver until the guard plate is bent through so much, that it can be inserted into the lower edge of the window of the motor lantern.

Page 16

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 14

Revision 02

Article No 771076102

Issue 01/2010

pic 8

Pull up screw driver only so far as is absolutely

necessary to insert the guard plate into the

window. If the guard plate doesn´t stick fast in

the window after installation: Dismantle g

uard plate once again, flatten it and

install again.

8.4 Removal of the Back Pull Out Assembly

The back pull out assembly consists of all pump parts except the volute casing (102V). As the pumps are constructed in block design, the volute casing (102V) can remain on the foundation and in the piping, if it´s not the volute casing itself, which must be repaired.

 Drain volute casing (102V) via drain plug (912.11).  Loosen screws of existing sealing or flushing

pipings.

 Loosen screws of support food (183) from the

foundation (not existing on all sizes).

 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.

pic 9

 Loosen hexagen head bolt (901.11) from the

casing.

 Using the jack screws provided (901.42), separate

the Back Pull Out Assembly from the casing.

8.5 Removal of Impeller

Notice 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. 8.8.1.

 Loosen impeller nut with a sensitive hit on the

wrench (right-hand thread). If necessary back up with a pry bar in the cross boring of the stud shaft (in clamp area).

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

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

Be sure to locate pry bars under impeller vanes

to prevent damage to the impeller.

 For further dismounting, and for installation, the

Back Pull Out Assembly should be placed in a vertical position. Prevent assembly from tipping!

pic 10

8.6 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).

8.7 Removal of Stub Shaft

 Loosen screws (920.41) and pull motor with stub

shaft (210) out of the motor lantern (341).

 Loosen radial stub shaft screwing (904.41 and

904.42) (stud bolts) and deduct stub shaft (210) from motor shaft. For support (break loose) you can insert a solid screw driver into the cross boring, press it against the front face of the motor and move both shafts against each other.

Page 17

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 15

Revision 02

Article No 771076102

Issue 01/2010

8.8 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). It is recommended in most cases to replace mech. seal, ball bearings and seals (flat seal, O-rings).

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 mech. seal and the bearings Deposits on the impeller (230), in the volute casing (102V) or on the casing cover must be removed.

8.8.1 Clearance at impeller

Suction side of impeller

Back vanes of impeller

Drive side of impeller

Only with pump size 100-65-315 125-80-315 125-100-315 150-125-315

Nominal diameter D (mm)

60 68

100 120 135

155 175

220

min. 0,15 0,17 0,20 0,22 0,25

new

max. 0,19 0,22 0,24 0,27 0,30

Radial clearance s (mm)

worn 0,78 0,85 0,90 1,05 1,15

new 0,8 - 1,2 Axial clearance a (mm)

worn max. 1,7

When the wea

r 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

supplied 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.

8.9 Mounting

8.9.1 General

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

reassembling the pump.

 For tight tolerances e.g. between stub shaft (210)

and motor shaft or impeller (230) and shaft (210), as well as thread, use suitable anti-galling compound (e.g. Molykote / Never-Seeze), so that the next mounting and dismounting will be easier.

Anti-

galling compound must be compatible with

the pumpage.

 Screws should be tightened, with the following

torque:

Screw torque in Nm

Location

Screw

Size

Lubricated

threads

Dry threads

M12 35 50 M16 105 150

Casing Screws

M20 210 305 M10 35 50 M12 60 90

All other scres

M16 150 220

 Do not use excessive force.  For mounting of stub shaft refer to chapter 8.9.2.  For mounting of mech. seal refer to separate

"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 8.8.1).

 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 do not forget to install

and connect all security devices.

8.9.2 Mounting of Stub Shaft

 Insert key in the motor stump.  Put anti-galling compound onto the motor stump

(see point 8.9.1).

 Push stub shaft up the motor shaft to measure A

(see pict. 11 and chart).

 Drill countersink into motorshaft, appr. 2-3 mm

depth, through the radial bore in the motor shaft (see pict. 11), by useing a twistdrill with 90° tip.

 Remove cuttings out of the stud hole (e.g. with

compressed-air), screw in and make safe thread pins (904.41 and 904.42) (e.g. with Omnifit 100 M or Loctite).

 Check smooth running of stub shaft opposite to

motor flange with a dial gauge. The pointer deflection of the dial gauge must not exceed 0,1 mm.

Page 18

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 16

Revision 02

Article No 771076102

Issue 01/2010

pic 11

Measure A by motor size

Type

80 90 100 112 132 160 180 200 40-25-160 157 157 197 197 197 232 - 40-25-200 157 157 197 197 197 232 - 40-25-250 162 162 202 202 202 237 237 237 50-32-160 157 157 197 197 197 232 - 50-32-200 157 157 197 197 197 232 - 50-32-250 162 162 202 202 202 237 237 237 50-32-315 - - 202 202 197 237 237 237 65-40-160 157 157 197 197 197 232 - 65-40-200 157 157 197 197 197 232 232 65-40-250 162 162 202 202 202 237 237 237 65-40-315 - - 202 202 197 237 237 237 80-50-160 157 157 197 197 197 232 232 80-50-200 157 157 197 197 202 232 232 232 80-50-250 - 162 202 202 202 237 237 237 80-50-315 - - 202 202 202 237 237 237 100-65-160 162 162 202 202 202 237 237 237 100-65-200 - 162 202 202 202 237 237 237 100-65-250 - 162 202 202 206 237 237 237 100-65-315 - - 206 206 202 241 241 241 125-80-160 - 162 202 202 202 237 237 237 125-80-200 - 162 202 202 202 237 237 237 125-80-250 - - 202 202 202 237 237 237 125-80-315 - - - 206 206 241 241 241 125-100-200 - - 202 202 202 237 237 237 125-100-250 - - 216 216 216 251 251 251 125-100-315 - - - - 206 241 241 241 150-125-250 - - - - 216 251 251 251 150-125-315 - - - - - 241 241 241 200-150-250 - - - - - 251 251 251

9. 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 VDMA

24296).

To ensure optimum availability, we recommend

that suitable quantities of spare parts are held in

stock, es

pecially if these are made from special

materials and in the case of mechanical se

als,

because of the longer delivery times.

Number of pumps (incl. stand-by pumps)

2 3 4 5 6/7 8/9 10/+ Spare Parts Number of spare parts Impeller 1 1 1 2 2 2 20% Wear ring 2 2 2 3 3 4 50% Shaft with keys and nuts 1 1 1 2 2 2 20% Joints for pump casing sets

4 6 8 8 9 12 150%

other joints sets

4 6 8 8 9 10 100%

Mech. seal sets

1 1 2 2 2 3 25%

Ordering spare parts

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.

Store spare parts in dry and clean rooms.

9.2 Stand-by pumps

It is essential that a sufficient number of stand-

by pumps are kept ready for use in plants where

failure of a pump could endanger human life or

cause damage to property or hig

h costs.

Regular checks should be carried out to ensure

that such pumps are always ready for use (see

Point 6.8).

Store stand-by pumps according to point 6.8.

Page 19

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 17

Revision 02

Article No 771076102

Issue 01/2010

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.

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

Temperature in shaft sealing too high

Temperature at the bearing too high

Pump leaking

Leakage rate at shaft sealing too high

Cause

Solution

■

Back-pressure too high

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)

■ ■

■

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

■ ■

Speed too high reduce speed

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

■ ■

Speed too low increase speed (check available motor power)

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

■ ■

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

■

Flow too big reduce flow (throttle discharge valve)

■ ■

Impeller diameter too big use smaller impeller

■ ■

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

■ ■

Pump and/or pipes not completely filled with liquid fill

vent

■ ■ ■

Pump or suction/intake pipe blocked clean

■ ■

Air pocket in pipeline vent

improve course of pipe

■ ■ ■

■ ■

Suction height too big / NPSH of system too small

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

■ ■ ■

Air being sucked in increase liquid level

check if suction pipe is vacuum-tight

■ ■ ■

Air being sucked in through shaft sealing clean sealing pipe

increase sealing pressure replace shaft sealing

■ ■

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

electrician)

■ ■

■

Inner components suffering from wear replace worn parts

■ ■ ■

Density and/or viscosity of liquid handled is too high seek assistance

■

Lines and roughness at shaft replace parts

■

Deposits on mechanical seal

clean replace mechanical seal if necessary if necessary provide additional rinsing or quench

■

Impeller out of balance

remove blocks/deposits replace impeller if broken or unevenly worn check shafts to ensure that they are running true

■ ■

■ ■ ■

Forces in pipeline too high (pump unit under strain) change (support pipes, use compensators, etc.)

is foundation plate/frame properly cast in place?

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

■ Sealing insufficient tighten screws replace sealing

■

Bearing damaged replace

■

Relief fittings insufficient

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

re given on

ordering

■ System-related vibrations (resonance) seek assistance

Page 20

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 18

Revision 02

Article No 771076102

Issue 01/2010

11. Motor Operating Instructions

The following instructions must be followed

exactly, to guarantee the safety at the

installation, at the operation and at the

intenance of the motor. All persons should

be directed to the present manual which are

performing these tasks. The neglect of the

instructions can cause the loss of the

guarantee.

Electrical connections

Make sure that the rated voltage corresponds to

the supply voltage.

Ground the pump before making any other

connection.

We recommend that a high sensitivity

differential switch (30 mA) be installed as extra

protection against lethal electric shocks in the

event of faulty grounding.

Connect the pump to the mains using a multiple-pole switch or other device ensuring multiple-pole disconnection (interruption of all the supply wires) from the mains, with a contact separation of at least 3 mm. Remove the terminal board cover by first removing the screws. Carry out the connections as indicated on the back of the terminal board cover, and as shown in fig. 3 - 4. The single-phase version has a built-in overload protection; the three-phase version must be equipped by the user with a magneto-thermal switch or magnetic starter with overload and undervoltage protection, a thermal relay and fuses installed upstream. The overload relay must be set to the motor current rating. The thermal relay may be set to a current value slightly lower than the full load value when the electric pump is definitely underloaded, but the thermal overload protection must not be set to current values higher than the full load values.

Checking the rotation direction of electric pumps with three-phase motors.

The direction of rotation may be checked before the pump is filled with the liquid to be pumped, provided it is run for very short starts only.

The pump must not be run until it is filled with

liquid.

Continuous dry running will damage the

mechanical seal beyond repair.

If the direction of rotation is not anti-clockwise when facing the pump from the suction side interchange two supply leads.

Fault finding chart

PROBLEM PROBABLE CAUSE POSSIBLE

REMEDIES

1. The pump doesn’t start

A) No electrical power B) Blown fuses: B1 Because inadeguate (blowing current too low) B2 Because the motor or the supply cable are damaged C) Overload protection previously tripped

A) Supply electrical power

B1 Replace fuses with adequate ones

B2 Repair the motor or replace the cable

C)Reset the protection (if it trips again see problem 2)

2. Overload protection trips: – accidentaly

A) Momentary loss of a phase

– systematically

C) Incorrect setting of the motor switch D) The pump’s

delivery is higher than

the rated one

E) Dense and viscous

liquid

C) Set to rated current D) Close the delivery valve until the capacity returns to the rated value E) Determine the actual power requirements and replace the motor accordingly

Page 21

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 19

Revision 02

Article No 771076102

Issue 01/2010

Page 22

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 20

Revision 02

Article No 771076102

Issue 01/2010

Installation Manual - Single mech. seal without shaft sleeve (Design code S1..2)

1. Safety Instructions

Every person, who is responsible for the

installation, removal, operation, start-

up and

maintenance of the shaft seal, must also have

read and understood the Installation, Operation

nd Maintenance Instruction of the particular

pump and especially chapter 8.1 "General

remarks" and chapter 8.2 "General", and follow

the instructions under any circumstances!

For pumps which are designed in conformity

with the Directive 94/9/EG (Atex95)

for

environment endangered to explosion, the

additional Operating Instruction for explosion

protection of the mech. seal must be noticed.

The following descriptions are only valid commonly, as far as they refer to the inner design of the mech. seal. For possible particularities refer to the data sheet of the mech. seal or instruction of the mech. sealmanufacturer.

2. Design Description

This shaft seal is a single mech. seal with installation dimensions acc. to EN 12756 (DIN 24960) design "K". API plan 02 / ISO plan 00. Due to the patented Cyclon Seal Chamber no additional flushing of the mech. seal chamber is required.

For data of materials and application range of used mech. seals refer to the data sheet in the operation instruction resp. the order confirmation.

Index of parts:

161 Casing cover 210 Shaft 230 Impeller

412.21 O-ring 433 Mech. seal

502.31*) W ear ring 527 a) Fixing ring 560 b) Pin

904.31 a) Set screw

904.32*) Set screw 922 Impeller nut

940.31 Key

*) optional a) not for all designs b) only for mech. seals with PTFE-O-rings

This leaflet is subject to alteration!

Nominal

size of

mech. seal

∅d1 ∅d

A B

∅d

33 33 48 42,5 7,5 50 19 43 43 61 45 7,5 52,5 28 53 53 73 47,5 10 57,5 38

Page 23

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 21

Revision 02

Article No 771076102

Issue 01/2010

3. Removal of mech. seal

For that purpose use the appropriate sectional drawing and the enclosed data sheet of the mech. seal.

 Remove and disassemble the pump acc. to the

Installation, Operation and Maintenance Instructions including chapter 8.6.

 Remove fixing ring (527) (if existing) and rotating

part of the mech. seal (433) from shaft (210). Refer to the enclosed data sheet of the mech. seal, if set screws are to be loosened at the mech. seal at first.

 Remove stationary part of the mech. seal (433)

out of the casing cover (161).

 Clean drilling for stationary seal rng (∅d7) in the

casing cover (161) and surface of shaft (210).

The reuse of mech. seals, which have already

been used for a longer time, can lead to leak

ing

at the seal faces after reinstallation. Therefore

the replacement of the mec

h. seal through a

new one is recommended. The dismounted

mechanical seal can be reconditioned by the

manu

facturer and serve as a replacement

mech.seal.

4. Installation of a mech. seal

For that purpose use the sectional drawing and data sheet of the mech. seal.

It is only allowed to install mech. seals, which

have a certificate of Conformity acc. the

Directive 94/9/EG.

On changing the mech. seal type resp. the

mech. seal manufacturer the data regarding

max. operating temperature of the pumped

medium

and temperature class must be

checked again.

Pay attention to the utmost cleanness!

Especially the seal faces must be clean, dry and

damaged. Don´t apply lubrication on the seal

faces of the mech. seal.

 If a lubricant is provided with the replacement

mech. seal, you should use this.

Use mineral grease or oil only, if you are

completely sure that the elastomers of the

mech. seal are oil resistant. Use no silicone.

Use only lubricants when you are sure that

there can´t occur any dangerous react

ions

between the pumpage and the lubricant.

Make all required parts available, so that

assembly can be completed quickly. The

lubricants are only effective for a short time.

After that the axial movability and, thus, the

automatic adjustment of the elastomeres is lost.

Don´t push elastomers over sharp edges. If

necessary use mounting devices.

 Press the stationary part of the mech. seal in the

casing cover (161). For this you can eventually use a stamp with a soft surface. Unequal load can lead to cracking of the seal face.

 Don´t damage seal face!  Pay attention that the stationary ring is in solid

contact with the casing cover. The seal face must be installed perpendicular to the shaft.

 If a pin (560) is existing, be careful that it fits into

the slot of the mech. sealing, without touching the mech. seal.

 Push the rotating unit of the mech. seal on the

shaft (210).

 Complete the face on the impeller side of the

mech. seal exactly with the shaft (measure l1K). For mech. seals without own set screws the fixing ring (527) serves as a stop.

Push mech. seals with bellows in such a way,

that the bellow is compressed and not stretched

(danger of tearing apart!).

 Further mounting and installation of the pump

referring to the repair instructions.

Page 24

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 22

Revision 02

Article No 771076102

Issue 01/2010

Installation Manual - Single mech. seal with quench without shaft sleeve (Design code S4..2)

1. Safety Instructions

Every person, who is responsible for the

installation, removal, operation, start-

up and

maintenance of the shaft seal, must also have

read an

d understood the Installation, Operation

and Maintenance Instruction of the particular

pump and especially chapter 8.1 "General

remarks" and chapter 8.2 "General", and follow

the instructions under any circumstances!

For pumps which are designed in conf

ormity

with the Directive 94/9/EG (Atex95) for

environment endangered to explosion, the

additional Operating Instruction for explosion

protection of the mech. seal must be noticed.

2. Description

This shaft seal is a single mech. seal with installation dimensions acc. EN 12756 (DIN 24960) design "K", form "U". API plan 62 / ISO plan 09. The resistance of the materials in the mech. seal chamber (especially of elastomeres) against the quench liquid has to be noticed. The quench chamber must be flown through by the quench liquid without pressure. For connection refer to the following sectional drawing.

The liquid of the quench must be selected in

such way that there can not occur any

dange

rous reactions with the handled fluid. The

liquid of the quench can be contaminated due to

the handled fluid, therefore the operator must

care for an adequate disposal.

Because of the patented Cyclone Seal Chamber no additional flushing of the seal chamber is necessary. For description of materials and operational range of the mech. seals supplied please refer to the data sheet in the Operation Instruction resp. order confirmation.

QI ... Quench suction (471Q) Q0 ... Quench discharge (471Q)

Page 25

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 23

Revision 02

Article No 771076102

Issue 01/2010

Index of parts:

161 Casing cover 210 Shaft 230 Impeller

412.21 O-ring

412.32 O-ring

433 Mech. seal 471Q Quench cover

502.31*) W ear ring

527 a) Fixing ring

542.31 Throttle bush

560 b) Pin

904.31 a) Grub screw

904.32*) Grub screw

923 Impeller nut

*) optional a) not for all designs b) only for mech. seals with PTFE-O-rings

Subject to techn. alterations!

Nominal

size of

mech. seal

∅d1 ∅d

A B

∅d

QI, Q0

33 33 48 42,5 7,5 50 19

1/4-

NPT

43 43 61 45 7,5 52,5 28

3/8-

NPT

53 53 73 47,5 10 57,5 38

3/8-

NPT

3. Removal of mech. seal

For that purpose use the appropriate sectional drawing and the enclosed data sheet of the mech. seal.  Remove and disassemble the pump acc. to the

Installation, Operation and Maintenance Instructions including chapter 8.6.

 Remove fixing ring (527) (if existing) and rotating

part of the mech. seal (433) from shaft (210).

 Refer to the enclosed data sheet of the mech.

seal, if set screws are to be loosened at the mech. seal at first.

 Remove casing cover (161) together with quench

cover (471Q). Use hexagonal screws (901.42) as jack screws.

 Pull stationary part of the mech. seal (433) and

throttle bush (542.31) out of quench cover (471Q).

 Clean drilling for stationary seal ring (∅d7) in the

quench cover (471Q) and surface of the shaft (210).

The reuse of mech. seals, which have already

been used for a longer time, can lead to lea

king

at the seal faces after reinstallation. Therefore

the replacement of the mech. seal through a

new one is recommended. The dismounted

mechanical seal can be reconditioned by the

manu

facturer and serve as a replacement

mech. seal.

4. Installation of mech. seal

For that purpose use the appropriate sectional drawing and the enclosed data sheet of the mech. seal.

It is only allowed to install mech. seals, which

have a certificate of Conformity acc. the

Directive 94/9/EG. On changing the mech. sea

l type resp. the

mech. seal manufacturer the data regarding

max. operating temperature of the pumped

medium and temperature class must be

checked again.

Pay attention to the utmost cleanness!

Especially the seal faces must be clean, dry and

undamaged.

Don´t apply lubrication on the seal

faces of the mech. seal.

 If a lubricant is provided with the replacement

mech. seal, you should use this.

Use mineral grease or oil only, if you are

completely sure that the elastomers of the

mech. seal are oil resistant. Use no silicone.

Use only lubricants when you are sure that

there can´t occur any dangerous reactions

between the pumpage and the lubricant.

Make all required parts available, so that

assembly can be completed quickly. The

lubricants are only

effective for a short time.

After that the axial movability and, thus, the

automatic adjustment of the elastomeres is lost.

Don´t push elastomers over sharp edges. If

necessary use mounting devices.

 Put throttle bush (542.31) into quench cover

(471Q) carefully.

 Press the stationary part of the mech. seal in the

quench cover (471Q). For this you can eventually use a stamp with a soft surface. Unequal load can lead to cracking of the seal face.

 Don´t damage seal face!  Pay attention that the stationary ring is in solid

contact with the quench cover. The seal face must be installed perpendicular to the shaft.

 If a pin (560) is existing, be careful that it fits into

the slot of the mech. sealing, without touching the mech. seal.

 Insert casing cover (161) carefully, until it fits

axially in the bearing frame lantern (344).

 Push the rotating unit of the mech. seal on the

shaft (210).

Page 26

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 24

Revision 02

Article No 771076102

Issue 01/2010

 Adjust the face on the impeller side of the mech.

seal exactly on measure A. For mech. seals without own set screws the fixing ring (527) serves as a stop.

Push mech. seals with bellows in such a way,

that the bellow is compressed and not stretched

(danger of tearing apart!).

Use anti-

friction device (Molykote, etc.) between

shaft sleeve and shaft only, if you are sure tha

no dangerous reactions between pumped liquid

and anti-friction device can occur.

 Further assembly and installation of pump acc.

chapter 8 of Installation, Operation and Maintenance Instruction.

Before starting the pump connect flushing

system for quench and put it into operation.

Page 27

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 25

Revision 02

Article No 771076102

Issue 01/2010

Design: S1...2 Single mech. seal, unbalanced (DIN 24960, l

/ EN 12756, design K, form U), Impeller with

back vanes

You find the shaft sealing of your pump on the data sheet / the order confirmation. Refer to chapter 3.1.1, Design

coding system, as well.

125-100-200 125-100-250 150-125-250 200-150-250

80-50-315 100-65-160 100-65-200 100-65-250 125-80-160 125-80-200 125-80-250

65-40-160 65-40-200 65-40-250 65-40-315 80-50-160 80-50-200 80-50-250

40-25-160 40-25-200 40-25-250 50-32-160 50-32-200 50-32-250 50-32-315

Valid for

Part name:

Volute casing

Casing cover

Support foot

Pump alignment

Stub shaft

Impeller

Motor lanterne

Gasket

O-ring

Mech. seal

Wear ring

Fixing ring

Washe

Bevelwasher

Bevelcup

Washer

Guard plate

Flange motor

Hexagonal screw

Stud

Grub screw

Drain plug

Hexagonal nut

Impeller nut

Key

No.

102 V

161

183 ***)

183P **)

210

230

341

400

412.21

433

502.11 *)

527 **)

554.41

554.42 ***)

554.43 ***)

554.44 ***)

681

801

901.11

901.31 **)

901.42

901.43 ***)

902

.41

904.11 *)

904.31 **)

904.41

904.42

912.11

920.41

922

940.31

*) ... optional **) ... not for all designs ***) ... with IEC-Motor sizes: 160MA,

160M, 160L, 180M, 180L, 200L, 200LA, only

Subject to techn. alterations!

Not to scale!

Page 28

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 26

Revision 02

Article No 771076102

Issue 01/2010

Design: S1...2 Single-mech. seal, unbalanced (DIN 24960, l

/ EN 12756, design K, form U), Impeller with

balancing holes

For the shaft sealing of your pump refer to data sheet / order confirmation. See chapter 3.1.1, design coding

system, as well.

150-125-315 125-100-315 125-80-315 100-65-315 Valid for type:

Part name

Volute casing

Casing cover

Support foot

Pump alignme

Stub shaft

Impeller

Motor lantern

Gasket

O-ring

Mech. seal

Wear ring

Fixing ring

Washer

Bevelwasher

Bevelcup

Washer

Guard plate

Flange motor

Hexagonal screw

Stud

Grub screw

Drain plug

Hexagonal nut

Impeller nut

Key

No.

102 V

161

183 ***)

183P **)

210

230

341

400

412.21

433

502.11

502.31 *)

527 **)

554.41

554.42 ***)

554.43 ***)

554.44 ***)

681

801

901.11

901.31 **)

901.42

901.43 ***)

902.41

904.11 *)

904.32 *)

904.31 **)

904.41

904.42

912.11

920.41

922

940.31

*) ... optional **) ... not for all designs ***) ... only with IEC-motor sizes:

160MA, 160M, 160L, 180M, 180L, 200L, 200LA

Subject to techn. alterations!

Not to scale!

Page 29

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 27

Revision 02

Article No 771076102

Issue 01/2010

Design: S4...2 Single mech. seal, unbalanced (DIN 24960, l

/ EN 12756, design K, form U), with quench,

Impeller with back vanes

For shaft sealing of your pump refer to data sheet / order confirmation. See chapter 3.1.1, Design coding system, as

well.

125-100-200 125-100-250 150-125-250 200-150-250

80-50-315 100-65-160 100-65-200 100-65-250 125-80-160 125-80-200 125-80-250

65-40-160 65-40-200 65-40-250 65-40-315 80-50-160 80-50-200 80-50-250

40-25-160 40-25-200 40-25-250 50-32-160 50-32-200 50-32-250 50-32-315

Valid for type:

Part name

Volute casing

Casing cover

Support foot

Pump alignment

Stub shaft

Impeller

Motor lantern

Gasket

O-ring

Mech. seal

Quench cover

Wear ring

Fixing ring

Throttle bush

Washer

Bevelwasher

Bevelcup

Washer

ard plate

Flange motor

Hexagonal screw

Stud

Grub screw

Drain plug

Hexagonal nut

Impeller nut

Key

No.

102 V

161

183 ***)

183P **)

210

230

341

400

412.21

412.32

433

471Q

502.11 *)

527 **)

542.31

554.41

554.42 ***)

554.43 ***)

554.44 ***)

681

801

901.11

901.31 **)

901.42

901.43 ***)

902.31

902.41

904.11 *)

904.31 **)

904.41

904.42

912.11

920.31

920.41

922

940.31

*) ... optional **) ... not for all designs ***) ... only with IEC-Motor sizes:

160MA, 160M, 160L, 180M, 180L, 200L, 200LA

Subject to techn. alteration!

Not to scale!

Page 30

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 28

Revision 02

Article No 771076102

Issue 01/2010

Design: S4...2 Single mech. seal, unbalanced (DIN 24960, l

/ EN 12756, design K, form U), with quench,

Impeller with balancing holes

For shaft sealing of your pump refer to data sheet / order confirmation. See chapter 3.1.1, Design coding system, as

well.

150-125-315 125-100-315 125-80-315 100-65-315 Valid for type:

Part name

Volute casing

Casing cover

Suppo

rt foot

Pump alignment

Stub shaft

Impeller

Motor lantern

Gasket

O-ring

Mech. seal

Quench cover

Wear ring

Fixing ring

Throttle bush

Washer

Bevelwasher

Bevelcup

Washer

Guard plate

Flange motor

Hexagonal screw

Stud

Grub screw

Drain plug

Hexagonal nut

Impeller nut

Key

No.

102 V

161

183 ***)

183P **)

210

230

341

400

412.21

412.32

433

471Q

502.11 *)

502.31 *)

527 **)

542.31

554.41

554.42 ***)

554.43 ***)

554.44 ***)

681

801

901.11

901.31 **)

901.42

901.43 ***)

902.31

902.41

904.11 *)

904.31 **)

904.32 **)

904.41

4.42

912.11

920.31

920.41

922

940.31

*) ... optional **) ... not for all designs ***) ... only with IEC-Motor sizes:

160MA, 160M, 160L, 180M, 180L, 200L, 200LA

Subject to techn. alterations!

Not to scale!

Page 31

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 29

Revision 02

Article No 771076102

Issue 01/2010

Connections:

Bearing bracket

Code Number

Connection

24 32, 42, 48 PM1 *) 1 pressure gaging 1/4-18 NPT PM2 *) 1 pressure gaging 1/4-18 NPT

D 1 draining (casing) 3/8-18 NPT

DL 1 draining (lantern) G 1/2

QI **) 1 Quench-suction 1/4-18 NPT 3/8-18 NPT

QO **) 1 Quench-discharge 1/4-18 NPT 3/8-18 NPT

*) ... optional, possible with designs S2..1 and S4..2 **) ... only with design S4..2

Subject to techn. alterations!

Not to scale

Page 32

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 30

Revision 02

Article No 771076102

Issue 01/2010

Dimensional drawing - For the type of your pump refer to data sheet / order confirmation. See chapter 3.1.1, design coding system.

H can vary depending on the motor manufacturer G ... weight for pump without motor in kg Tolerances acc. to DIN EN 735 Dimensions in mm Subject to techn. alterations! Not to scale!

Pump DN

a b g2 h1 h2 m1 m2 n1 n2 p1 p2 s1 s2 x

ICB 40-25-160 .... - ... 40 25 80 50 10 132 160 100 70 240 190 15 30 14 13,5 100

ICB 40-25-200 .... - ... 40 25 80 50 10 160 180 100 70 240 190 15 30 14 13,5 100

ICB 40-25-250 .... - ... 40 25 100 65 10 180 225 125 95 320 250 15 30 14 13,5 100

ICB 50-32-160 .... - ... 50 32 80 50 10 132 160 100 70 240 190 15 30 14 13,5 100

ICB 50-32-200 .... - ... 50 32 80 50 10 160 180 100 70 240 190 15 30 14 13,5 100

ICB 50-32-250 .... - ... 50 32 100 65 10 180 225 125 95 320 250 15 30 14 13,5 100

ICB 50-32-315 .... - ... 50 32 125 65 10 200 250 125 95 345 280 15 30 14 13,5 100

ICB 65-40-160 .... - ... 65 40 80 50 10 132 160 100 70 240 190 15 30 14 13,5 100

ICB 65-40-200 .... - ... 65 40 100 50 10 160 180 100 70 265 212 15 30 14 13,5 100

ICB 65-40-250 .... - ... 65 40 100 65 10 180 225 125 95 320 250 15 30 14 13,5 100

ICB 65-40-315 .... - ... 65 40 125 65 10 200 250 125 95 345 280 15 30 14 13,5 100

ICB 80-50-160 .... - ... 80 50 100 50 10 160 180 100 70 265 212 15 30 14 13,5 100

ICB 80-50-200 .... - ... 80 50 100 50 10 160 200 100 70 265 212 15 30 14 13,5 100

ICB 80-50-250 .... - ... 80 50 125 65 10 180 225 125 95 320 250 15 30 14 13,5 100

ICB 80-50-315 .... - ... 80 50 125 65 10 225 280 125 95 345 280 15 30 14 13,5 100

ICB 100-65-160 .... - ... 100 65 100 65 10 160 200 125 95 280 212 15 30 14 13,5 100

ICB 100-65-200 .... - ... 100 65 100 65 10 180 225 125 95 320 250 15 30 14 13,5 140

ICB 100-65-250 .... - ... 100 65 125 80 10 200 250 160 120 360 280 15 30 18 13,5 140

ICB 100-65-315 .... - ... 100 65 128 80 10 225 280 160 120 400 315 15 30 18 13,5 140

ICB 125-80-160 .... - ... 125 80 125 65 10 180 225 125 95 320 250 15 30 14 13,5 140

ICB 125-80-200 .... - ... 125 80 125 65 10 180 250 125 95 345 280 15 30 14 13,5 140

ICB 125-80-250 .... - ... 125 80 125 80 10 225 280 160 120 400 315 15 30 18 13,5 140

ICB 125-80-315 .... - ... 125 80 125 80 10 250 315 160 120 400 315 15 30 18 13,5 140

ICB 125-100-200 .... - ... 125 100 125 80 10 200 280 160 120 360 280 15 30 18 13,5 140

ICB 125-100-250 .... - ... 125 100 140 80 10 225 280 160 120 400 315 15 30 18 13,5 140

ICB 125-100-315 .... - ... 125 100 140 80 10 250 315 160 120 400 315 15 30 18 13,5 140

ICB 150-125-250 .... - ... 150 125 140 80 10 250 355 160 120 400 315 15 30 18 13,5 140

ICB 150-125-315 .... - ... 150 125 140 100 10 280 355 200 150 500 400 15 30 22 13,5 140

ICB 200-150-250 .... - ... 200 150 160 100 10 280 375 200 150 500 400 15 30 22 13,5 180

Page 33

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 31

Revision 02

Article No 771076102

Issue 01/2010

Pump Bmax g1 ~H h U n4 n5 w ~G

ICB 40-25-160 .... - 80 119 15 408 176 - - - - 31

ICB 40-25-160 .... - 90 119 15 457 176 - - - - 31

ICB 40-25-160 .... - 100 144 15 530 216 - - - - 37

ICB 40-25-160 .... - 112 144 15 539 216 - - - - 37

ICB 40-25-160 .... - 132 150 35 666 216 20 - - - 37

ICB 40-25-160 .... - 160 175 60 771 251 45 210 180 206 43

ICB 40-25-200 .... - 80 119 15 408 176 - - - - 39

ICB 40-25-200 .... - 90 119 15 457 176 - - - - 39

ICB 40-25-200 .... - 100 144 15 530 216 - - - - 45

ICB 40-25-200 .... - 112 144 15 539 216 - - - - 45

ICB 40-25-200 .... - 132 150 15 666 216 - - - - 45

ICB 40-25-200 .... - 160 175 60 815 251 45 210 180 206 54

ICB 40-25-250 .... - 80 171 15 421 189 - - - - 60

ICB 40-25-250 .... - 90 171 15 470 189 - - - - 60

ICB 40-25-250 .... - 100 171 15 543 229 - - - - 65

ICB 40-25-250 .... - 112 171 15 552 229 - - - - 65

ICB 40-25-250 .... - 132 171 15 679 229 - - - - 65

ICB 40-25-250 .... - 160 175 15 828 264 - 210 180 219 75

ICB 40-25-250 .... - 180 180 20 859 264 5 210 180 219 75

ICB 40-25-250 .... - 200 225 65 964 264 50 280 250 219 75

ICB 50-32-160 .... - 80 119 15 408 176 - - - - 31

ICB 50-32-160 .... - 90 119 15 457 176 - - - - 31

ICB 50-32-160 .... - 100 144 15 530 216 - - - - 37

ICB 50-32-160 .... - 112 144 15 539 216 - - - - 37

ICB 50-32-160 .... - 132 150 35 666 216 20 - - - 37

ICB 50-32-160 .... - 160 175 60 771 251 45 210 180 206 43

ICB 50-32-200 .... - 80 119 15 408 176 - - - - 39

ICB 50-32-200 .... - 90 119 15 457 176 - - - - 39

ICB 50-32-200 .... - 100 144 15 530 216 - - - - 45

ICB 50-32-200 .... - 112 144 15 539 216 - - - - 45

ICB 50-32-200 .... - 132 150 15 666 216 - - - - 45

ICB 50-32-200 .... - 160 175 60 815 251 45 210 180 206 54

ICB 50-32-250 .... - 80 171 15 421 189 - - - - 60

ICB 50-32-250 .... - 90 171 15 470 189 - - - - 60

ICB 50-32-250 .... - 100 171 15 543 229 - - - - 65

ICB 50-32-250 .... - 112 171 15 552 229 - - - - 65

ICB 50-32-250 .... - 132 171 15 679 229 - - - - 65

ICB 50-32-250 .... - 160 175 15 828 264 - 210 180 219 75

ICB 50-32-250 .... - 180 180 20 859 264 5 210 180 219 75

ICB 50-32-250 .... - 200 225 65 964 264 50 280 250 219 75

ICB 50-32-315 .... - 100 201 15 543 229 - - - - 102

ICB 50-32-315 .... - 112 201 15 552 229 - - - - 102

ICB 50-32-315 .... - 132 201 15 679 229 - - - - 102

ICB 50-32-315 .... - 160 201 15 828 264 - 210 180 219 112

ICB 50-32-315 .... - 180 201 15 859 264 - 210 180 219 112

ICB 50-32-315 .... - 200 225 65 964 264 50 280 250 219 112

ICB 65-40-160 .... - 80 124 15 408 176 - - - - 32

ICB 65-40-160 .... - 90 124 15 457 176 - - - - 32

ICB 65-40-160 .... - 100 144 15 530 216 - - - - 39

ICB 65-40-160 .... - 112 144 15 539 216 - - - - 39

ICB 65-40-160 .... - 132 150 35 666 216 20 - - - 39

ICB 65-40-160 .... - 160 175 60 815 251 45 210 180 206 44

ICB 65-40-200 .... - 80 139 15 408 176 - - - - 44

ICB 65-40-200 .... - 90 139 15 457 176 - - - - 44

ICB 65-40-200 .... - 100 144 15 530 216 - - - - 50

ICB 65-40-200 .... - 112 144 15 539 216 - - - - 50

ICB 65-40-200 .... - 132 150 15 666 216 - - - - 50

ICB 65-40-200 .... - 160 175 35 815 251 20 210 180 206 60

ICB 65-40-200 .... - 180 180 60 846 251 45 210 180 206 60

ICB 65-40-250 .... - 80 171 15 421 189 - - - - 62

ICB 65-40-250 .... - 90 171 15 470 189 - - - - 62

ICB 65-40-250 .... - 100 171 15 543 229 - - - - 68

ICB 65-40-250 .... - 112 171 15 552 229 - - - - 68

ICB 65-40-250 .... - 132 171 15 679 229 - - - - 68

ICB 65-40-250 .... - 160 175 15 828 264 - 210 180 219 77

ICB 65-40-250 .... - 180 180 20 859 264 5 210 180 219 77

ICB 65-40-250 .... - 200 225 65 964 264 50 280 250 219 77

Page 34

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 32

Revision 02

Article No 771076102

Issue 01/2010

Pump Bmax g1 ~H h U n4 n5 w ~G

ICB 65-40-315 .... - 100 201 15 543 229 - - - - 102

ICB 65-40-315 .... - 112 201 15 552 229 - - - - 102

ICB 65-40-315 .... - 132 201 15 679 229 - - - - 102

ICB 65-40-315 .... - 160 201 15 828 264 - 210 180 219 112

ICB 65-40-315 .... - 180 201 15 859 264 - 210 180 219 112

ICB 65-40-315 .... - 200 225 65 964 264 50 280 250 219 112

ICB 80-50-160 .... - 80 141 15 408 176 - - - - 36

ICB 80-50-160 .... - 90 141 15 457 176 - - - - 36

ICB 80-50-160 .... - 100 144 15 530 216 - - - - 43

ICB 80-50-160 .... - 112 144 15 539 216 - - - - 43

ICB 80-50-160 .... - 132 150 15 666 216 - - - - 43

ICB 80-50-160 .... - 160 175 35 815 251 20 210 180 206 49

ICB 80-50-160 .... - 180 180 60 846 251 45 210 180 206 49

ICB 80-50-200 .... - 80 157 15 408 176 - - - - 45

ICB 80-50-200 .... - 90 157 15 457 176 - - - - 45

ICB 80-50-200 .... - 100 157 15 530 216 - - - - 51

ICB 80-50-200 .... - 112 157 15 539 216 - - - - 51

ICB 80-50-200 .... - 132 157 15 666 216 - - - - 51

ICB 80-50-200 .... - 160 175 35 815 251 20 210 180 206 60

ICB 80-50-200 .... - 180 180 60 846 251 45 210 180 206 60

ICB 80-50-200 .... - 200 225 85 951 251 70 280 250 206 60

ICB 80-50-250 .... - 90 181 15 470 189 - - - - 69

ICB 80-50-250 .... - 100 181 15 543 229 - - - - 75

ICB 80-50-250 .... - 112 181 15 552 229 - - - - 75

ICB 80-50-250 .... - 132 181 15 679 229 - - - - 75

ICB 80-50-250 .... - 160 181 15 828 264 - 210 180 219 84

ICB 80-50-250 .... - 180 181 20 859 264 5 210 180 219 84

ICB 80-50-250 .... - 200 225 65 964 264 50 280 250 219 84

ICB 80-50-315 .... - 100 212 15 543 229 - - - - 108

ICB 80-50-315 .... - 112 212 15 552 229 - - - - 108

ICB 80-50-315 .... - 132 212 15 679 229 - - - - 108

ICB 80-50-315 .... - 160 212 15 828 264 - 210 180 219 118

ICB 80-50-315 .... - 180 212 15 859 264 - 210 180 219 118

ICB 80-50-315 .... - 200 225 40 964 264 25 280 250 219 118

ICB 100-65-160 .... - 80 164 15 421 189 - - - - 49

ICB 100-65-160 .... - 90 164 15 470 189 - - - - 49

ICB 100-65-160 .... - 100 164 15 543 229 - - - - 55

ICB 100-65-160 .... - 112 164 15 552 229 - - - - 55

ICB 100-65-160 .... - 132 164 15 679 229 - - - - 55

ICB 100-65-160 .... - 160 175 40 828 264 25 210 180 219 64

ICB 100-65-160 .... - 180 180 40 859 264 25 210 180 219 64

ICB 100-65-160 .... - 200 225 85 964 264 70 280 250 219 64

ICB 100-65-200 .... - 90 173 15 470 189 - - - - 53

ICB 100-65-200 .... - 100 173 15 543 229 - - - - 58

ICB 100-65-200 .... - 112 173 15 552 229 - - - - 58

ICB 100-65-200 .... - 132 173 15 679 229 - - - - 58

ICB 100-65-200 .... - 160 175 15 828 264 - 210 180 219 68

ICB 100-65-200 .... - 180 180 20 859 264 5 210 180 219 68

ICB 100-65-200 .... - 200 225 65 964 264 50 280 250 219 68

ICB 100-65-250 .... - 90 193 18 470 189 - - - - 74

ICB 100-65-250 .... - 100 193 18 543 229 - - - - 80

ICB 100-65-250 .... - 112 193 18 552 229 - - - - 80

ICB 100-65-250 .... - 132 193 18 679 229 - - - - 80

ICB 100-65-250 .... - 160 193 18 828 264 - 210 180 219 89

ICB 100-65-250 .... - 180 193 18 859 264 - 210 180 219 89

ICB 100-65-250 .... - 200 225 48 964 264 30 280 250 219 89

ICB 100-65-315 .... - 100 221 18 555 241 - - - - 115

ICB 100-65-315 .... - 112 221 18 564 241 - - - - 115

ICB 100-65-315 .... - 132 221 18 691 241 - - - - 115

ICB 100-65-315 .... - 160 221 18 840 276 - 210 180 231 125

ICB 100-65-315 .... - 180 221 18 871 276 - 210 180 231 125

ICB 100-65-315 .... - 200 225 18 976 276 - 210 180 231 125

ICB 125-80-160 .... - 90 188 15 470 189 - - - - 56

ICB 125-80-160 .... - 100 188 15 543 229 - - - - 62

ICB 125-80-160 .... - 112 188 15 552 229 - - - - 62

ICB 125-80-160 .... - 132 188 15 679 229 - - - - 62

ICB 125-80-160 .... - 160 188 15 828 264 - 210 180 219 71

Page 35

Installation, Operation and Maintenance Instruction

Model ICB

ICB 100-english page 33

Revision 02

Article No 771076102

Issue 01/2010

Pump Bmax g1 ~H h U n4 n5 w ~G

ICB 125-80-160 .... - 180 188 20 859 264 5 210 180 219 71

ICB 125-80-160 .... - 200 225 65 964 264 50 280 250 219 71

ICB 125-80-200 .... - 90 202 15 470 189 - - - - 63

ICB 125-80-200 .... - 100 202 15 543 229 - - - - 69

ICB 125-80-200 .... - 112 202 15 552 229 - - - - 69

ICB 125-80-200 .... - 132 202 15 679 229 - - - - 69

ICB 125-80-200 .... - 160 202 15 828 264 - 210 180 219 78

ICB 125-80-200 .... - 180 202 20 859 264 5 210 180 219 78

ICB 125-80-200 .... - 200 225 65 964 264 50 280 250 219 78

ICB 125-80-250 .... - 100 229 18 543 229 - - - - 91

ICB 125-80-250 .... - 112 229 18 552 229 - - - - 91

ICB 125-80-250 .... - 132 229 18 679 229 - - - - 91

ICB 125-80-250 .... - 160 229 18 828 264 - 210 180 219 100

ICB 125-80-250 .... - 180 229 18 859 264 - 210 180 219 100

ICB 125-80-250 .... - 200 229 23 964 264 5 280 250 219 100

ICB 125-80-315 .... - 112 240 18 564 241 - - - - 129

ICB 125-80-315 .... - 132 240 18 691 241 - - - - 129

ICB 125-80-315 .... - 160 240 18 840 276 - 280 250 231 139

ICB 125-80-315 .... - 180 240 18 871 276 - 280 250 231 139

ICB 125-80-315 .... - 200 240 18 976 276 - 280 250 231 139

ICB 125-100-200 .... - 100 217 18 543 229 - - - - 90

ICB 125-100-200 .... - 112 217 18 552 229 - - - - 90

ICB 125-100-200 .... - 132 217 18 679 229 - - - - 90

ICB 125-100-200 .... - 160 217 23 828 264 5 210 180 219 99

ICB 125-100-200 .... - 180 217 23 859 264 5 210 180 219 99

ICB 125-100-200 .... - 200 225 48 964 264 30 280 250 219 99

ICB 125-100-250 .... - 100 227 18 565 251 - - - - 100

ICB 125-100-250 .... - 112 227 18 574 251 - - - - 100

ICB 125-100-250 .... - 132 227 18 701 251 - - - - 100

ICB 125-100-250 .... - 160 227 18 850 286 - 220 180 241 109

ICB 125-100-250 .... - 180 227 18 881 286 - 220 180 241 109

ICB 125-100-250 .... - 200 227 23 986 286 5 280 250 241 109

ICB 125-100-315 .... - 132 257 18 691 241 - - - - 139

ICB 125-100-315 .... - 160 257 18 840 276 - 280 250 231 150

ICB 125-100-315 .... - 180 257 18 871 276 - 280 250 231 150

ICB 125-100-315 .... - 200 257 18 976 276 - 280 250 231 150

ICB 150-125-250 .... - 132 249 18 701 251 - - - - 114

ICB 150-125-250 .... - 160 249 18 850 286 - 280 250 241 123

ICB 150-125-250 .... - 180 249 18 881 286 - 280 250 241 123

ICB 150-125-250 .... - 200 249 18 986 286 - 280 250 241 123

ICB 150-125-315 .... - 160 263 20 840 276 - 280 250 231 149

ICB 150-125-315 .... - 180 263 20 871 276 - 280 250 231 149

ICB 150-125-315 .... - 200 263 20 976 276 - 280 250 231 149

ICB 200-150-250 .... - 160 293 20 850 286 - 280 250 241 163

ICB 200-150-250 .... - 180 293 20 881 286 - 280 250 241 163

ICB 200-150-250 .... - 200 293 20 986 286 - 280 250 241 163

Flange dimensions DNS, DND*)

ISO PN16 ISO PN25 ANSI Class 150RF

DN C d D K L DN C d D K L NPS C d D K L

25 16 65 115 85 4x14 - - - - - - 1 16 51 115 79,5 4x16 32 18 78 140 100 4x19 32 20 78 140 100 4x19 1 1/2 18 73 140 98,5 4x16 40 19 88 150 110 4x19 40 19 88 150 110 4x19 1 1/2 19 73 150 98,5 4x16 50 20 102 165 125 4x19 50 20 102 165 125 4x19 2 20 92 165 120,5 4x19 65 20 122 185 145 4x19 65 22 122 185 145 8x19 2 1/2 20 105 185 139,5 4x19

80 20 128 200 160 8x19 80 24 138 200 160 8x19 3 20 128 200 152,5 4x19 100 24 157 230 180 8x19 100 24 162 235 190 8x22 4 24 157 230 190,5 8x19 125 24 186 255 210 8x19 125 26 186 270 220 8x22 5 24 186 255 216 8x22 150 25,5 216 285 240 8x22 - - - - - - 6 25,5 216 285 241,5 8x22 200 29 270 345 295 12x22 - - - - - - 8 29 270 345 298,5 12x22

*) ... For size of flanges, as well as, the nominal pressure refer to data sheet / order confirmation. See chapter 3.1.1, Design coding system, as well.