Johnson Controls TopClean AS User Manual
Instruction Manual
TopClean AS
Hygienic, Self-priming
Liquid Ring Pumps
IM-AS/02.00 GB-JPAB (0412)
CE – Declaration of conformity
Manufacturer
Johnson Pump
Box 1436
SE- 701 14 Örebro
Sweden
We declare under our sole responsibility that the product:
Pump Series AS
CE declaration of conformity (Ann.II.A, 98/37/EEC)
to wich this declaration refers, is conform to safety requirements according
to 98/37/EEC norms and amendments
Manufacturer declaration (Ann. II.B, 98/37/EEC)
cannot be operated before the machine in which is assembled, will be declared in conformity with safety requirements according to 98/37/EEC norms
and amendments.
Örebro, Sweden, 01/03/2007
Stefan Ring
Manager Quality & Environment
Index
1.0 Introduction ...................................................................................................... 3
2.0 Symbols ...................................................................................................... 3
3.0 Safety warnings ................................................................................................ 3
4.0 Transportation, receipt and transferring of goods ....................................... 4
4.1 Transportation .............................................................................................................. 4
4.2 Receipt .......................................................................................................................... 4
4.3 Transferring .................................................................................................................. 4
5.0 Description ...................................................................................................... 5
5.1 Sound pressure level.................................................................................................... 5
6.0 Non-permitted uses.......................................................................................... 6
7.0 Installation ...................................................................................................... 6
7.1 Suction and inflow conditions .................................................................................... 6
7.2 Piping ........................................................................................................................... 6
7.3 Electrical connection ................................................................................................... 7
8.0 Operation ...................................................................................................... 7
8.1 Preliminary operations and starting .......................................................................... 7
8.2 Operating checks ......................................................................................................... 8
8.3 Extended stop .............................................................................................................. 8
8.4 Cleaning the pump ...................................................................................................... 8
9.0 Spare parts ...................................................................................................... 8
10.0 Seals ................................................................................................. 9
11.0 Disassembly and Assembly AS-series ......................................................... 10
11.1 General instructions .................................................................................................. 10
11.2 O-rings and lip seals .............................................................................................. 10
11.3 Shutdown .............................................................................................. 10
11.4 Disassembly .............................................................................................. 11
11.4.1 Removal of pump casing and impeller – AS 40, 50, 60, 65 and 80 .......... 11
11.4.2 Removal of pump casing and impeller – AS 42 and AS 52 ...................... 11
11.4.3 Seal disassembly ............................................................................................ 12
11.4.3.1 T execution ......................................................................... 12
11.4.3.2 V execution ......................................................................... 12
11.4.3.3 Q execution......................................................................... 12
11.4.4 Bearing removal ............................................................................................ 13
11.5 Assembly .............................................................................................. 13
11.5.1 Clearances .............................................................................................. 13
11.5.2 Pump assembly AS 40, 50, 60, 65................................................................. 14
11.5.3 Seal assembly .............................................................................................. 14
IM-AS/02.00 GB (0412)
1
11.5.3.1 T execution .......................................................................... 14
11.5.3.2 V execution .......................................................................... 14
11.5.3.3 Q execution .......................................................................... 15
11.5.4 Assembly of pump casing and impeller assembly ........................................
– AS 40, AS 50, AS 60, AS 65 and AS 80 ................................................... 15
11.5.5 Pump cover and Impeller assembly – AS 42 and AS 52 ........................... 16
12.0 Spare parts lists and sectional drawings ...................................................... 17
12.1 Spare part list AS 40, 50, 60-65, 80 .......................................................................... 17
12.2 AS 40 – Execution T, Q, V........................................................................................ 18
12.3 AS 50 – Execution T, Q, V........................................................................................ 19
12.4 AS 60-65 – Execution T, Q, V .................................................................................. 20
12.5 AS 80 – Execution T, Q, V........................................................................................ 21
12.6 Spare part list AS 42, 52 ............................................................................................ 22
12.7 AS 42 – Execution T, Q, V........................................................................................ 23
12.8 AS 52 – Execution T, Q, V........................................................................................ 24
13.0 Dimensions and weights .............................................................................. 25
13.1 AS 40-50-60-65-80 with shroud 1450 rpm ............................................................... 25
13.2 AS 40-50-60-65-80 without shroud 1450 rpm ......................................................... 25
13.3 AS 42-52 with shroud 1450 rpm ............................................................................... 26
13.4 AS 42-52 with shroud 1450 rpm ............................................................................... 26
14.0 Trouble shooting chart .............................................................................. 27
15.0 Disposal of the pump .............................................................................. 28
2
IM-AS/02.00 GB (0412)
1.0 Introduction
• Read the instructions carefully and keep them for future consultation.
• Johnson Pump reserves the right to make any changes to the documentation it
deems necessary without being obliged to update publications that have already
been issued.
•When requesting information, spare parts or assistance, always specify the pump
type and serial number in order to ensure fast and efficient service: the complete
code is given on the plate and in the purchase documents.
Serial No.
No.
kW
Nastagatan 19, Örebro, Sweden · Tel +46 (0)19 21 83 00
Name plate
2.0 Symbols
TopClean
Item
r.p.m.
Volt
Pump type
Hz
Warning: Pay great attention to the text parts indicated by this symbol.
Danger: The non-observance of instructions can cause serious damage
to persons and/or objects.
Danger:Only skilled personnel is allowed to carry out operations
concerning the electric parts.
3.0 Safety warnings
When the pump is working the following occurs:
• Electric parts are in tension.
•Mechanical parts are moving.
• Pump body, pipelines and articulations are under internal pressure. Therefore do not
remove any protection or locking, do not loosen screws or clampings, as this can
cause serious damages to persons or objects. The clamp joining the pump casing and
the cover must be well tightened and it should not be easily unscrewed by hand. The
tightening of the clamp must be carried out by means of a key and not by hand.
• Non-observance of inspection and maintenance can cause damages to persons and
objects, especially when dangerous or toxic liquids are pumped.
•When pumping liquids at a temperature over 60°C, adequate protection and
warning signals are required.
•When you buy a pump with bare shaft, motor coupling operations have to be
•Operations on the electric parts have to be carried out by skilled personnel,
• Installation must ensure adequate ventilation, in order to cool the engine, as well as
IM-AS/02.00 GB (0412)
carried out according to technical directions and law, providing adequate
rotections for joints, gear belts, etc.
according to technical directions and law, on authorisation of the responsible
installer.
enough space for maintenance operations.
3
Before carrying out any operation which requires to disassembly of the pump
(inspection, cleaning, seal replacement, etc.), the following preliminary operations have
to be carried out:
• Switch off engine tension and disinsert electric connection.
• Close valves on suction and outlet pipelines, in order to avoid the risk of inundation.
•Use adequate protection for hands and face, if the pump contains liquids which are
hazardous to health (for example acids, solvents, etc.).
• Consider whether the liquid which flows out of the pump when disassembling is
dangerous and arrange for adequate safety measures.
4.0 Transportation, receipt and transferring of goods
4.1 Transportation
The packings of all AS pumps are defined when making the order. Unless prior arrangements
are given, goods will be packed only for transit conditions and not for long-term storage; in case
it should be necessary to store the pumps outside, you are requested to cover the pumps
appropriately in order to protect the electrical parts (motor) from rain, dust, humidity etc.
4.2 Receipt
Upon receipt of goods the integrity of the packaging must be verified in order to identify
possible damages to the content during transfer, and to claim immediately from the carrier.
Should any damage be ascertained, the following procedure must be observed:
• Collect the goods with receipt.
• Take the necessary pictures showing the damages.
• Notify the carrier of the suffered damages, by registered airmail – including the
pictures taken.
4.3 Transferring
Carry the packed pumps as close as possible to the place of installation by means of appropriate
lifting devices and unpack them. During this operation take care, as unsteady parts could fall
down.
The material used for packing (wood, paper, cellophane, etc.) should be properly disposed of,
according to the corresponding rules in force in receiver’ s country.
After unpacking the pump, use special lifting belts and move the pump-motor-set to the place
of installation; never use the eyebolts on the motor to move the pump, as the eyebolts are for
moving the motor only.
In versions complete with shroud,
take the shroud off before moving the
pump-motor-set, in order to avoid
damages.
4
IM-AS/02.00 GB (0412)
5.0 Description
The pumps of series AS are centrifugal side channel self-priming with star-shaped impeller; the
ports are located on the longitudinal axe with the suction located on the front of the pump
cover. All models have threaded connections for fittings according to DIN 11851 standard
(unless otherwise requested). The pump front cover is easy to open to improve cleaning and
inspection operations; all models are fitted with mechanical seals and the materials used for the
components of mechanical seal are chosen according to the liquid to be pumped.
Designed in close-coupled version, fitted with indepandant standard electric motors B5 shape,
IP 55 protection (unless otherwise requested).
These pumps are designed for applications where the liquid to be pumped :
• is not subject to pollution of any kind,
• is at a temperature between -30°C and +140°C,
•must under no circumstances come into contact with the outside environment,
• is chemically aggressive.
5.1 Sound pressure level
The sound pressure level of self-priming pumps is the following (see table):
The measurement has been made by means of a phon-meter placed at 1 m distance from the pump
and at a height of 1.6 m from the ground.
Preliminary condition is that the pump is fixed correctly; the above mentioned values do not take
into account external noise sources (e.g. valves, abrupt hydraulic deflections).
Pump type dB(A)
AS 40 < 80
AS 42 81-85
AS 50 81-85
AS 52 86-90
AS 60 86-90
AS 65 86-90
AS 80 86-90
IM-AS/02.00 GB (0412)
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6.0 Non-permitted uses
Do not use the pump with a suction pressure greater than the specified value (0.5 times
the discharge head generated by the pump).
The pump must always be used in an environment appropriate to the level of protection
of the motor. Always check this on the motor plate before installation.
The pump may not be used in environments which require a higher level of protection or
a higher specification motor or electrical parts.
Components complying with the safety standards for the environment in question must
be used.
7.0 Installation
7.1 Suction and inflow conditions
(NPSH = Net Positive Suction Head)
NPSH of system (available NPSH)
In order to ensure that pump operation is free from cavitation, it is essential to observe
the maximum permitted suction lift ha geo max or the minimum allowable head hc geo
min. NPSH of pump (required NPSH)
The centrifugal pumps can operate correctly only if vapour has not formed inside. For
this reason the static head at the reference point for the NPSH is the centre of the
impeller, that is the point of intersection of the pump shaft axis with the vertical plane
that passes through the external points of the blade inlet corners.
NPSHnec. is the value required by the pump, expressed in metres, obtained from the
performance curve. In practice 0.5 m should be added to this value as a safety margin.
7.2 Piping
In order to prevent the creation of harmful stresses, the suction and discharge pipes must
be connected to the pump ports without the use of force. These pipes must also be
supported independently avoiding causing stresses on the pump. The internal diameter
must be the same size as the pump connections. It must in any case not be smaller to
avoid head loss and/or poor performances. Always use elbows with large radius. If the
pipe diameter changes along the line, use reduction cones, choosing the ones that are
most suitable for avoiding the formation of air pockets (Fig. 1).
The suction pipe must be as short as possible and rise as it moves towards the pump if it
is sucking from a tank, if on the other hand the pump is below the level of the liquid, the
pipe should descend slightly. If the pump is used for transporting hot liquids, fit expansion joints to compensate any expansion of the piping. The maximum velocity of the
liquid in the suction pipe must not be greater than 3 m/s. Velocities between 1 and 2 m/s
are recommended.
The suction pipe must be designed in such a way as to prevent air from entering the
pump. For this reason, when sucking from a tank located at a lower level, the pipe must
reach below the free surface of the liquid. Avoid creating obstacles which could increase
suction losses disrupting smooth fluid flow. Make sure that there are no restrictions,
NO
YES
Fig. 1
6
IM-AS/02.00 GB (0412)
7.3 Electrical connection
Make the electrical connection only after the hydraulic connection has been completed; set up
the motor control system in conformity with the technical standards and regulations in force
(EN 60204-1): in particular a manual electric power switch must be installed with adequate
current switching capacity; devices for overcurrent and overload protection (e.g. fuses,
automatic switches, etc.) must also be fitted, plus, if necessary, a device to prevent accidental
restarting.
Check that the main frequency and voltage and the available power are suitable for the motor
installed. All the material used for the electrical connection (cables, cable clamps, switches and
shielding) must have a suitable level of protection for the environment in which it is installed.
Be sure to use cables of sufficient cross-section for the current shown on the motor plate so as
to prevent them from overheating. Before doing anything else, make the motor’s earth
connection, using the terminal on the motor and a cable of sufficient cross-section. The cables
may be connected to the terminal board using either a delta or star arrangement. Follow the
data given on the motor plate for the main voltage, as shown in the diagram in fig 2; ensure that
the terminals are clean and tight and not under stress.
When starting, the motor’s current absorption increases briefly to 5-6 times the nominal value.
If the mains supply is unable to sustain this increase in absorption, use a star-delta starter or
other kind of device (e.g. an autotransformer).
Johnson Pump will accept no responsibility for damage to property and/or injury to persons
caused by failure to comply with technical standards and regulations in force.
Lower
voltage
Fig 2
8.0 Operation
8.1 Preliminary operations and starting
When first starting, fill the pump with liquid so as to create the pressure drop required for
suction. When starting subsequently the quantity of liquid that remains in the pump will be
sufficient to ensure self-priming even if the pipe is empty. Make sure that the pump does not
become completely empty in the event of installation under a vacuum or to a siphon. If
necessary, fit a check valve.
• Check that the pump turns freely under hand pressure.
• Check that the clamp joining the pump casing and the cover is well tightened and that
it cannot be easily unscrewed by hand. The tightening of the clamp must be carried out
by means of a key and not by hand.
Higher
voltage
• Check that the pump turns in the market direction.
• Check that any gate valves installed on the suction and discharge pipelines are open.
• Start the pump and check the turns direction; before restarting it is extremely important to
IM-AS/02.00 GB (0412)
7
8.2 Operating checks
• If the pump does not generate the required discharge head rapidly, facilitate
priming by stopping the pump and adding liquid.
• Check that the absorption of the motor does not exceed the value specified on the
plate.
• The pump must always work smoothly and without vibrations.
•Do not operate without liquid and in any case avoid prolonged operation with the
discharge gate valve closed.
• With series AS pumps never close discharge side completely.
•Mechanical seal: check that there is no leakage along the shaft.
8.3 Extended stop
When stopping the pump for a longer time, empty the pump completely and wash it
accurately in order to avoid the formation of scales and/or encrustations. When starting
the pump again, please follow the above mentioned instructions.
8.4 Cleaning the pump
The pump does not require any special washing procedures. The washing cycles
normally used for the plant in which it is installed are quite satisfactory. When using the
pump for liquids that tend to harden or crystallize, always make sure it is washed before
periods when the machine is to be taken out of operation. This will ensure durability of
the seal and of the pump itself.
It is the user’s responsibility to ensure that the washing liquids are compatible with the
process liquid and the pump.
9.0 Spare parts
Denomination Number of pumps
Mechanical seal 1 2 3 4 4
Pump bearing 1 1 1 2 2
O-ring seal 2 3 5 6 7
O-ring seal nut 2 3 5 6 7
Recommended spare part for two years of operation according to the
number of pumps installed – vdma standard
Johnson Pump declines all responsibility for damage or injury resulting from the use of
non-original spare parts
(Including reserve)
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IM-AS/02.00 GB (0412)
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