Product Specification Sheet
X-Cel House, Chrysalis Way, Langley Bridge, Eastwood, Nottinghamshire NG16 3RY
Tel: +44 (0) 1773 302 660 | Email: sales@northridgepumps.com | Website: www.northridgepumps.com
Operating instructions
KRAL screw pumps.
Series L
Magnetic coupling
Observe safety instructions for persons with cardiac pacemaker, metallic implant or
neurostimulator.
OIL 02en-GB
Edition 2019-03
Original instructions
Table of contents
1 About this document ..................................................... 4
1.1 General information .......................................................4
1.2 Associated documents ..................................................4
1.3 Target groups ................................................................4
1.4 Symbols.........................................................................5
1.4.1 Danger levels ....................................................5
1.4.2 Danger signs.....................................................5
1.4.3 Symbols in this document .................................5
2 Safety .............................................................................. 6
2.1 Proper use .....................................................................6
2.2 Foreseeable misuse ......................................................6
2.3 Obligations of the operator-owner .................................6
2.4 Safety instructions .........................................................7
2.4.1 Fundamental safety instructions .......................7
2.4.2 Dangers at magnetic coupling systems ............7
2.4.3 Dangers during transportation ..........................7
2.4.4 Dangers during storage ....................................7
2.4.5 Dangers during installation ...............................8
2.4.6 Dangers during removal....................................8
2.4.7 Dangers during connection work ......................8
2.4.8 Dangers during operation .................................8
2.4.9 Dangers during servicing ..................................9
2.4.10 Dangers during maintenance............................9
2.4.11 Dangers during disposal ...................................9
3 Identification................................................................. 10
3.1 Type code....................................................................10
3.2 Rating plate .................................................................11
4 Technical data .............................................................. 11
4.1 Operating limits............................................................11
4.2 Sound pressure level...................................................12
4.3 Required NPSH values................................................12
4.4 Weights........................................................................13
4.5 Materials ......................................................................14
4.6 Accessories .................................................................15
5 Function description.................................................... 15
5.1 Pump structure ............................................................15
5.2 Pump unit structure .....................................................15
5.3 Functional principle......................................................16
5.4 Housing variants..........................................................16
5.5 Magnetic coupling........................................................16
5.6 Overflow valve .............................................................17
6 Transportation, storage............................................... 17
6.1 Dangers during transportation .....................................17
6.2 Dangers during storage ...............................................17
6.3 Unpacking and checking the state of delivery .............17
6.4 Transporting the pump/pump unit................................18
6.5 Storing the pump .........................................................19
7 Preservation ................................................................. 19
7.1 Preservation table........................................................19
7.2 Preserving the inner surfaces......................................19
7.3 Preserving the outer surfaces......................................20
7.4 Removing the preservation..........................................20
8 Installation, removal .................................................... 21
8.1 Dangers during installation ..........................................21
8.2 Dangers during removal...............................................21
8.3 Installing the pump.......................................................21
8.4 Removing the pump.....................................................22
9 Connection.....................................................................23
9.1 Dangers during connection work .................................23
9.2 Connecting the pump to the pipe system.....................24
9.3 Connecting the pump unit to the power supply............25
10 Operation........................................................................25
10.1 Dangers during operation ............................................25
10.2 Commissioning ............................................................26
10.2.1 Cleaning the pipe system ................................26
10.2.2 Filling and venting the pump............................26
10.2.3 Checking the direction of rotation ....................28
10.2.4 Commissioning the pump ................................29
10.3 During operation ..........................................................30
10.3.1 Checking the operating pressure.....................30
10.3.2 Monitoring filters and/or strainers ....................31
10.3.3 Adjusting the overflow valve ............................31
10.3.4 Switching off the pump unit .............................32
10.4 Decommissioning.........................................................32
10.4.1 Decommissioning the pump ............................32
10.5 Recommissioning.........................................................33
10.5.1 Recommissioning the pump ............................33
11 Maintenance...................................................................33
11.1 Dangers during maintenance.......................................33
11.2 Required maintenance.................................................34
11.3 Ball bearing ..................................................................34
11.4 Maintaining the pump...................................................34
11.5 Maintaining the magnetic coupling...............................34
12 Servicing ........................................................................35
12.1 Dangers during servicing .............................................35
12.2 Wear ............................................................................35
12.2.1 Magnetic coupling............................................35
12.3 Replacing the overflow valve .......................................36
12.3.1 Removing the overflow valve...........................36
12.3.2 Installing the overflow valve.............................36
12.4 Replacing the magnetic coupling .................................37
12.4.1 Removing the outer rotor.................................37
12.4.2 Removing the inner rotor .................................38
12.4.3 Installing the inner rotor ...................................39
12.4.4 Installing the outer rotor...................................40
12.5 Replacing the ball bearing and screw set ....................42
12.5.1 Removing the ball bearing and screw set........42
12.5.2 Installing the ball bearing and screw set..........43
13 Disposal..........................................................................44
13.1 Dismantling and disposing of the pump ......................44
14 Troubleshooting ............................................................45
14.1 Possible faults..............................................................45
14.2 Troubleshooting ...........................................................45
15 Accessories ...................................................................47
15.1 Heating.........................................................................47
15.1.1 Possible types of heating.................................47
15.1.2 Electrical heating system.................................47
15.1.3 Fluid heating system........................................49
15.1.4 Heating system special design ........................50
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Operating instructions
16 Spare parts ................................................................... 50
16.1 Overview......................................................................50
16.2 Maintenance kits..........................................................51
16.2.1 Maintenance kit magnetic coupling.................51
16.3 Repair kits....................................................................52
16.3.1 Repair kit screw set LFI/LVI/LFT/LVT/LFM.....52
16.3.2 Repair kit overflow valve LFI/LVI/LFT/LVT/LFM
........................................................................52
16.3.3 Repair kit magnetic coupling...........................53
16.4 Completions.................................................................54
16.4.1 Completion type LFI/LVI/LFT/LVT/LFM ..........54
17 Appendix....................................................................... 55
17.1 Tightening torque for screws with metric screw threads
and head contact surfaces ..........................................55
17.2 Tightening torques for screw plugs with thread meas-
ured in inches and elastomer seal...............................55
17.3 Tightening torques for screws of tensioning elements
.....................................................................................55
17.4 Contents of the Declaration of Conformity...................56
Table of contents
Operating instructions
OIL 02en-GB Edition 2019-03
3
1 About this document
1.1 General information
1 About this document
1.1 General information
1.2 Associated documents
1.3 Target groups
These instructions form part of the product and must be kept for future reference. Furthermore please
observe the associated documents.
o Declaration of conformity according to EU Directive 2006/42/EC
o Manufacturer's declaration according to EU Directive 2014/68/EU
o Data sheet of the pump
o Technical documentation of the supplied components
Additional documents for ATEX version
o Declaration of conformity according to EU Directive 2014/34/EU
o ATEX supplementary instructions for usage in potentially explosive areas
The instructions are intended for the following persons:
o Persons who work with the product
o Operator-owners who are responsible for the use of the product
Information on the required qualification of the personnel is provided separately at the beginning of the
individual chapters in these instructions. The following table provides an overview.
Target group Activity Qualification
Transport
personnel
Mobile crane
operators,
crane operators,
forklift operators
Fitter Mounting,
Electrician Electrical
Trained
personnel
Tab.1: Target groups
Transportation,
unloading
Unloading,
positioning
connection
connection
Delegated task Trained personnel were instructed by the operator-owner in the task
Transport personnel are qualified personnel who carry out the transportation of products properly due to their training, knowledge and
experience and on the basis of the relevant provisions. Transport
personnel recognize and avoid possible dangers and damage to
property that are connected with this activity.
Mobile crane operators, crane operators and forklift operators are
qualified personnel who carry out work with cranes and forklifts
properly due to their training, knowledge and experience and on the
basis of the relevant provisions. Mobile crane operators, crane operators and forklift operators recognize and avoid possible dangers
and damage to property that are connected with this activity.
Fitters are qualified personnel who carry out the mounting work
properly due to their training, knowledge and experience and on the
basis of the relevant provisions. Fitters recognize and avoid possible dangers and damage to property that are connected with this
activity.
Electricians are qualified personnel who carry out work on electrical
equipment and installations properly due to their training, knowledge and experience and on the basis of the relevant provisions.
Electricians recognize and avoid possible dangers and damage to
property that are connected with this activity.
delegated to them and the possible dangers arising through improper behaviour.
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Operating instructions
1.4 Symbols
kg
1.4.1 Danger levels
Signal word Danger level Consequences of non-observance
DANGER Immediate threat of danger Serious personal injury, death
WARNING Possible threat of danger Serious personal injury, invalidity
CAUTION Potentially dangerous situation Slight personal injury
ATTENTION Potentially dangerous situation Material damage
1.4.2 Danger signs
Meaning Source and possible consequences of non-observance
Electrical voltage Electrical voltage causes serious physical injury or death.
1 About this document
1.4 Symbols
Magnetic field Magnetic field can cause serious physical injury or death.
Raised load Falling objects can result in serious physical injury or death.
Heavy load Heavy loads can result in serious back problems.
Risk of slipping Discharging pumped liquid and oils on the foundation or
Flammable substances Discharging pumped liquid and oils can be easily inflam-
Hot surface Hot surfaces of the pump unit can cause burns.
1.4.3 Symbols in this document
Meaning
Warning personal injury
Safety instruction
tread surfaces can cause falls with serious physical injury
or death.
mable and can result in serious burns.
Operating instructions
Prohibition sign cardiac pacemaker
Request for action
1.
2.
3.
Multi-step instructions for actions
Action result
Cross-reference
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2 Safety
2.1 Proper use
2 Safety
2.1 Proper use
o Use the pump solely for transporting lubricating liquids that are chemically neutral and that do not
contain gas or solid components.
o Use the pump only within the operating limits specified on the rating plate and in the chapter "Tech-
nical data". In the case of operating data that do not agree with the specifications on the rating
plate, please contact the manufacturer.
o The pump is designed specially for the operating pressure named by the customer. If the actual op-
erating pressure deviates notably from this design pressure, damage to the pump can also arise
within the specified operating limits. This applies both to notably higher as well as to notably lower
operating pressures. Under no circumstances may the minimum pressure lie below 2bar. In case
of any doubt, please contact the manufacturer.
2.2 Foreseeable misuse
o Any use that extends beyond the proper use or any other use is misuse.
o The product is not suitable for pumping liquids outside the operational limits.
o Any bypassing or deactivation of safety equipment during operation is prohibited.
2.3 Obligations of the operator-owner
The operator-owner is the person who operates the product commercially or permits a third party to
use it and who bears the legal responsibility for the product, the protection of the personnel and third
parties during its operation.
The product is used in industrial applications. The operator-owner is therefore subject to the statutory
obligations concerning occupational health and safety.
In addition to the safety instructions in these instructions, the regulations on safety, accident prevention
and environmental protection respectively valid for the range of application of the product are to be observed.
This results in the following obligations for the operator-owner:
o Observe the rules and regulations such as national standards, international standards and provi-
sions applicable at the site of use.
o Observe the obligations arising from occupational safety and from safety, accident protection and
environmental protection.
o Draw up a hazard assessment for the utilization of the product at the site of use.
o Draw up the operating guidelines for the operation of the product on the basis of the hazard assess-
ment.
o Keep the operating guidelines up-to-date during the entire operating life of the product, by ensuring
that the current version of the applicable rules and regulations are integrated.
o Ensure the qualification, instruction, information on dangers as well as regular training of the per-
sonnel.
o Specify clear responsibilities for all work on the product, for example for the installation, operation,
maintenance, troubleshooting.
o Keep the operating instructions available at the site of use - also for future use.
o Ensure that the operating instructions as well as the associated documents are read, understood
and observed by the personnel.
o Observe the safety regulations for handling dangerous pumped liquids and comply with the safety
data sheets. Pumped liquids can, for example, be hot, poisonous, combustible and caustic.
o Make personal protective equipment available and instruct their use.
o Equip systems with an increased potential of danger with protective equipment and/or alarm equip-
ment. The failure of a component may not result in injury and/or damage to property.
o Maintain and check protective equipment and alarm equipment regularly.
o Ensure the technically flawless state of the product during its entire operating life.
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Operating instructions
2.4 Safety instructions
2.4.1 Fundamental safety instructions
The following safety instructions must be observed strictly:
o Read these operating instructions carefully and observe them.
o Read the operating instructions of the components carefully and observe them.
o Have work only carried out by qualified personnel/trained personnel.
o Wear personal protective equipment and work carefully.
o Pumped liquids can be subject to high pressure and can result in personal injury and damage to
property in case of incorrect operation or damaged components.
o Pumped liquids can be hot, poisonous, combustible and caustic. Use corresponding protective
equipment.
o Observe the associated data sheets and safety regulations when handling dangerous materials.
o Avoid skin contact with system parts carrying liquids at operating temperatures exceeding 60°C.
o Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations. Neutralize residues.
o Keep the mounting surfaces, scaffolding, ladders, lifting platforms and tools clean in order to pre-
vent slipping or stumbling.
o If pressurized or energized components are damaged, shut down the pump immediately. Replace
the components or pump.
2 Safety
2.4 Safety instructions
2.4.2 Dangers at magnetic coupling systems
Magnetic fields from magnetic coupling systems (MCS) can influence the function and operational
safety of electrical and electronic devices. The following safety instructions must be observed.
The following safety instructions must be observed:
o Keep the MCS away from cardiac pacemakers. There is a danger to life!
§ Under no circumstances may persons with cardiac pacemakers perform installation, dismantling
or maintenance work.
o Persons with cardiac pacemakers must comply with the following safe distances to the MCS:
§ 3 m distance to the openly accessible MCS
§ 1 m distance to pump units with installed MCS
o Do not bring the MCS in the immediate area of PCs, data carriers and other electronic compon-
ents.
o Keep the MCS away from clocks, magnetized tools and measuring equipment as well as all mag-
netizable parts.
o Do not bring both the MCS parts together, as this can destroy the magnetic coupling system.
2.4.3 Dangers during transportation
The following safety instructions must be observed:
o Have all work only carried out by authorized transport personnel.
o Use intact and correctly dimensioned hoisting equipment.
o Ensure that the means of transport is in a flawless state.
o Ensure that the centre of gravity of the load is taken into consideration.
o Do not stand under raised loads.
Operating instructions
2.4.4 Dangers during storage
The following safety instructions must be observed:
o Observe the storage conditions.
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2 Safety
2.4 Safety instructions
2.4.5 Dangers during installation
2.4.6 Dangers during removal
2.4.7 Dangers during connection work
The following safety instructions must be observed strictly:
o Have all work carried out only by authorized qualified personnel.
o Before installation ensure that the operating limits, NPSH values and ambient conditions are ob-
served.
o Observe the tightening torques Ä Appendix,Page55.
o Ensure that all the components can be accessed and that maintenance work can be carried out
easily.
The following safety instructions must be observed strictly:
o Have all work carried out only by authorized qualified personnel.
o Before beginning work, let the pump unit cool down to the ambient temperature.
o Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
o Ensure that the collection tank for discharging pumped liquids is sufficiently large.
The following safety instructions must be observed strictly:
o Have all work on the pump and pipe system only carried out by authorized qualified personnel.
o Ensure that impurities cannot get into the pump and pipe system.
o Ensure that mechanical connections are mounted stress-free.
o Observe the tightening torques Ä Appendix,Page55.
o Have all the work on the electrical equipment only carried out by electricians.
o Before beginning work on the pump ensure that the electrical power supply is deenergized and is
secured against being switched back on.
o If the insulation of the electrical cables or wires is damaged, disconnect the power supply immedi-
ately.
2.4.8 Dangers during operation
The following safety instructions must be observed strictly:
o Have all work carried out only by authorized qualified personnel.
o Before commissioning ensure that a safety valve has been installed in the pipe system on the
pressure side before the first shut-off device.
o Before commissioning, make sure that the suction line and pump are filled.
o Pumped liquids can be hot, poisonous, combustible and caustic. Use corresponding protective
equipment.
o Ensure that the pump station is only operated within the operating limits.
o During a standstill ensure that the pressure in the pump does not exceed the inlet pressure.
o Ensure that during cooling down or heating up the pump is only subjected to slow temperature
changes.
o Ensure that existing safety equipment is not bypassed or activated during operation.
o Before decommissioning ensure that the electrical power supply is deenergized and is secured
against being switched back on.
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Operating instructions
2.4.9 Dangers during servicing
The following safety instructions must be observed strictly:
o Have all work carried out only by authorized qualified personnel.
o Before beginning work on the pump ensure that the electrical power supply is deenergized and is
secured against being switched back on.
o Before beginning work, let the pump unit cool down slowly to the ambient temperature. Avoid
rapid temperature changes.
o Pumped liquids can be hot, poisonous, combustible and caustic. Use corresponding protective
equipment.
o Ensure that the pump is depressurized and that shut-off devices are not operated uncontrolled.
o Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
o Ensure that the collection tank for discharging pumped liquids is sufficiently large.
o Observe the tightening torques Ä Appendix,Page55.
o Observe the operating instructions and data sheets of the components.
2.4.10 Dangers during maintenance
The following safety instructions must be observed strictly:
o Have all work carried out only by authorized qualified personnel.
o Before beginning work, let the pump unit cool down slowly to the ambient temperature. Avoid
rapid temperature changes.
o Pumped liquids can be hot, poisonous, combustible and caustic. Use corresponding protective
equipment.
o Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
o Ensure that the collection tank for discharging pumped liquids is sufficiently large.
o Observe the operating instructions and data sheets of the components.
2 Safety
2.4 Safety instructions
2.4.11 Dangers during disposal
The following safety instructions must be observed strictly:
o Neutralize residues.
Operating instructions
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9
3 Identification
LFI - 42.DCAP.00001
1
2
3
4
5
6
7
3.1 Type code
3 Identification
3.1 Type code
Fig.1: Type code
Item Classification Description
1 Type LFI
LFT
LFM
LFW
LVI
LVT
2 Size Corresponds to delivery rate in [l/min] at
3 Shaft seal A Standard mechanical seal
B Mechanical seal of hard material
C Standard radial shaft seal
D Magnetic coupling
F High-temperature radial shaft seal
H Mechanical seal balanced
X Special design
4 Pressure stage overflow valve B Pressure stage 16.0– 39.9 bar
C Pressure stage 40.0– 64.0 bar
X Special design
5 Heating A Without heating
B Electrical heating system
C Fluid heating system
X Special design
6 Completion P Pump with free shaft end
F Pump unit with pump bracket foot
V Pump unit without pump bracket foot
7 Version index For internal administration
Tab.2: Type code
o Pump with free shaft end
o Pump with inline flanges PN25/PN63
o Pump unit with or without pump bracket foot
o Pump with free shaft end
o Pump with overhead flanges PN25/PN63
o Pump unit with or without pump bracket foot
o Pump with free shaft end
o Pump with overhead flanges PN6/PN40
o Pump unit with or without pump bracket foot
o Pump with free shaft end
o Pump with overhead flanges PN25/PN40
o Pump unit with or without pump bracket foot
o Pump with free shaft end and pedestal
o Pump with inline flanges PN25/PN63
o Pump unit on pedestal for vertical mounting
o Pump with free shaft end and pedestal
o Pump with overhead flanges PN25/PN63
o Pump unit on pedestal for vertical mounting
1450min
-1
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Operating instructions
3.2 Rating plate
Typ | Type
Seriennr. | Serial no.
Tmin. / Tmax. ºC l/min
mm²/s
min
-
¹
bar
bar
KRAL AG, 6890 Lustenau, Austria www.kral.at
pD max. / ps max.
∆p
Jahr | Year
n
Q
Art.-Nr. | Item no.
Pumpen
1
2
3
5
4
10
7
9
8
6
Fig.2: Rating plate
4 Technical data
4.1 Operating limits
4 Technical data
3.2 Rating plate
1 Construction year
2 Max. operating overpressure
pressure-side/
Max. operating overpressure
suction-side
3 Temperature range
4 Serial number
5 Type
6 Article number
7 Differential pressure
8 Nominal delivery rate
9 Rated speed
10 Nominal viscosity
Size
Parameter Unit 5–85
Max. operating overpressure
o Pump with flange PN25/PN63
o Pump with flange PN6/PN40
[bar] 63
[bar] 40
Max. temperature of the pumped
liquid
o Magnetic coupling
Min. temperature for pump mater-
[°C] Customer-specific, contact the manufacturer
[°C] -10
ial
Min.–max. ambient temperature [°C] -10...50
Min.–max. viscosity [mm2/s] 1.5–10000
Speed max.
o At 50Hz
o At 60Hz
[min-1] 2900
[min-1] 3500
Max. inlet pressure
o Magnetic coupling
[bar] Customer-specific, contact the manufacturer
Tab.3: Operating limits
Operating instructions
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11
4 Technical data
4.2 Sound pressure level
4.2 Sound pressure level
4.3 Required NPSH values
Guide values at 1 m distance, 1450 min-1, 20 bar
Size
5–54 55–84
Max. sound pressure level±3[dB(A)]
Pump 58.0 59.0
Motor 62.0 62.0
Pump unit 63.5 64.0
Tab.4: Sound pressure level
The following table lists the required NPSH values during operation with a low-volatile pumped liquid
such as lubricating oil or hydraulic liquid. When pumped liquids have a readily volatile component content, the required NPSH values increase notably:
o Fuel oil requires an NPSH value of at least 6 mWC.
o In the case of liquids that contain water (for example heavy fuel oil) the values in the table have to
be increased by the vapour pressure of the water at the specified operating temperature.
The required NPSH values also need to be increased if there are gas contents, regardless of whether
they are dissolved or not. In case of any doubt, please contact the manufacturer.
Size Viscosity NPSH values [mWC] at speed
[min-1]
[mm2/s] 1450 1750 2900 3500 [mm2/s] 1450 1750 2900 3500
5 6 2.0 32 6 2.0
37 2.0 37 2.0
152 2.0 152 2.0 2.3 2.7
380 2.0 380 2.1 2.2 3.0 3.5
7.5 6 2.0 42 6 2.0 2.2 2.7
37 2.0 37 2.0 2.2 2.7
152 2.0 152 2.0 2.9 3.5
380 2.0 2.3 2.5 380 2.3 2.6 3.9 4.8
10 6 2.0 2.1 2.0 54 6 2.0 2.1 3.0 3.7
37 2.0 37 2.0 2.3 3.4 4.2
152 2.0 2.3 152 2.5 2.7 4.1 5.1
380 2.0 2.3 2.5 380 2.9 3.2 5.0 6.3
15 6 2.0 55 6 2.0 2.3
37 2.0 37 2.0 2.3
152 2.0 2.2 152 2.0 2.6 3.1
380 2.0 2.6 2.9 380 2.2 2.4 3.4 4.1
20 6 2.0 2.1 74 6 2.0 2.5 3.1
37 2.0 2.1 37 2.0 2.5 3.0
152 2.0 2.4 2.8 152 2.0 2.1 3.3 4.1
380 2.1 2.3 3.1 3.7 380 2.5 2.8 4.4 5.6
26 6 2.0 2.2 2.7 85 6 2.0 2.8 3.4
37 2.0 2.2 2.7 37 3.1 3.8
152 2.0 2.9 3.5 152 2.0 2.3 3.7 4.7
380 2.3 2.6 3.9 4.8 380 2.6 3.0 5.0 6.5
Tab.5: Required NPSH values
Size Viscosity NPSH values [mWC] at speed
[min-1]
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Operating instructions
4.4 Weights
Weights type LFI/LFT/LFM
Size of pump
5
7.5
Size of
motor
Weight of
the motor
[kg]
80 10 10 5.5 6.5 – –
90S 12 10 5.5 6.5 – –
20 6.0 7.0 – –
90L 14 10 5.5 6.5 – –
20 6.0 7.0 – –
100L 21 10 – – – –
20/22 – 10.0 13.5 14.5
30 – 11.0 – –
112M 28 10 – – – –
20/22 – 10.0 13.5 14.5
30 – 11.0 – –
132S 39 20/22 – 10.0 – 16.0
30 – 11.0 – –
40 – 11.5 – –
50 – 16.0 18.0 20.0
80 – – 19.0 22.0
132M 45 20/22 – 10.0 – 16.0
30 – 11.0 – –
40 – 11.5 – –
50 – 16.0 18.0 20.0
80/85 – – 19.0 22.0
160M 110 40 – – – –
50 – – 20.5 20.5
80 – – 21.0 25.5
160L 120 40 – – –
50 – – 20.5 20.5
80/85 – – 21.0 25.5
10
Magnet
power [Nm]
Weight of pump with free shaft end [kg]
9.0 14.0 17.5 33.0
Weight of pump bracket with magnetic coupling and screws [kg]
Tab.6: Weights type LFI/LFT/LFM
15
20
54
32
42
54
55
74
85
4 Technical data
4.4 Weights
Operating instructions
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13
4 Technical data
4.5 Materials
Weights type LVI/LVT
Size of pump
5
7.5
Size of
motor
Weight of
the motor
[kg]
80 10 10 5.5 5.5 – –
90S 12 10 5.5 5.5 – –
20 5.5 6.0 – –
90L 14 10 5.0 5.5 – –
20 5.5 6.0 – –
100L 21 10 – – – –
20/22 – 8.5 12.0 13.0
30 – 9.5 – –
112M 28 10 – – – 14.0
20/22 – 8.5 12.0 13.0
30 – 9.5 – –
132S 39 20 – 8.5 – 14.0
30 – 9.5 – –
40 – 10.0 – –
50 – 14.5 16.0 18.0
80 – – 17.5 20.0
132M 45 20/22 – 8.5 – 14.0
30 – 9.5 – –
40 – 10.0 – –
50 – 14.5 16.0 18.0
80/85 – – 17.5 20.0
160M 110 40 – – – –
50 – – 18.5 18.5
80 – – 19.0 23.5
160L 120 40 – – – –
50 – – 18.5 18.5
80/85 – – 19.0 23.5
10
Magnet
power [Nm]
Weight of pump with free shaft end [kg]
9.0 14.0 17.5 33.0
Weight of pedestal [kg]
2.0 2.0 3.0 3.0
Weight of pump bracket with magnetic coupling and screws [kg]
Tab.7: Weights type LVI/LVT
15
20
54
32
42
54
55
74
85
14
4.5 Materials
Part Material designation Material number
Pump housing EN-GJS-400-15 5.3106
Bearing cover EN-GJS-400 0.6020
End cover 16MnCrS5 1.7139
Screw set 16MnCrS5 1.7139
Tab.8: Materials
OIL 02en-GB Edition 2019-03
Operating instructions
5 Function description
7
8
9
10
21 3
5
4
6
11 12 13 14 1615
4.6 Accessories
4.6 Accessories
Notice The technical data of the accessories are specified separately Ä Accessories,Page47.
5 Function description
5.1 Pump structure
Fig.3: Pump structure
1 Idle screw 6 Shaft end pump (main screw)
2 Pump housing 7 Overflow valve
3 Balancing cylinder 8 Screw plug
4 Bearing cover 9 Balancing bush
5 Ball bearing 10 End cover
5.2 Pump unit structure
Fig.4: Pump unit structure
11 Pump 14 Inner rotor
12 Containment can 15 Outer rotor support
13 Outer rotor 16 Motor
Operating instructions
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15
5 Function description
5.3 Functional principle
5.3 Functional principle
5.4 Housing variants
Screw pumps are rotating pumps. Their displacement effect results from three rotating screws1 and6
and the enclosing pump housing2.
Radial support of the screw set is effected through the sliding contact in the pump housing that depends on lubrication by the pumped liquid. Screw pumps are therefore not suitable for dry running and
can only be used up to specific pressure limits and viscosity limits. Due to the narrow tolerances pumping of suspended solids is not possible.
Axial support of the main screw6 is carried out by a deep-groove ball bearing5. In order to reduce the
pressure, a balancing cylinder3 is mounted at the main screw. The idle screws also have an axial
thrust relief through balancing bushes9 at the suction-side end of the screws and core drilled holes to
the pressure chamber. An integrated overflow valve7 protects against excessive pressure that could
cause housing parts to burst.
The default direction of the rotation of the screw set is clockwise viewed from the motor and is marked
on the pump flange by an arrow.
The flow direction is marked on the pump housing by two arrows.
Housing Type Description
LFI/LVI Flange arrangement: Inline flange PN25/PN63
LFT/LVT Flange arrangement: Overhead flange PN25/PN63
LFM Flange arrangement: Overhead flange PN6/PN40
Tab.9: Housing variants
5.5 Magnetic coupling
The shaft end of the pump6 is enclosed by a containment can12, that is connected air-tight with the
motor-side flange of the pump. Therefore, it is not necessary to seal a rotating free shaft end against a
stationary seal housing. Special rotors equipped with powerful permanent magnets are used for transfer of torque from the motor to the pump. The inner rotor14 is fixed at the shaft end and driven by the
outer rotor13, which in turn is fixed to the shaft of the motor16. The torque is thus transferred contactfree by means of the magnetic field between the outer and inner rotor.
The containment can is made of a non-magnetic stainless steel which does not impede the forming of
magnetic flux lines between the rotors. The pressure discharge of the containment can occurs via a
core drilled hole in the main screw. Therefore, it can be assumed that the pressure in the containment
can approximately corresponds to the pressure on the suction side of the pump.
16
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Operating instructions
6 Transportation, storage
2
3
1
4
5.6 Overflow valve
5.6 Overflow valve
1 Screw plug
2 Adjusting screw
3 Pressure spring
4 Valve body
Fig.5: Overflow valve
The integrated overflow valve ensures that very high pressures that could result in housing parts bursting do not arise.
The overflow valve is purely there as a safety element for the pump and should not be used for control
or regulation purposes such as maintaining pressure. If the valve is kept open for too long under adverse operating conditions (high differential pressures and/or low viscosities) it will only take a few
minutes for the overflow valve and the valve seating to become damaged. As a result, the overflow
valve will leak permanently and there will be a corresponding reduction in the delivery rate. In addition
to this, circulation through the overflow valve for too long results in excess heating of the pump. This
reduces viscosity and can ultimately lead to pump failure.
It therefore has to be ensured through a safety valve at the system that the maximum operating pressure always lies under the opening pressure of the overflow valve.
Notice The opening pressure of the overflow valve is set to 110% of the differential pressure in the factory.
The overflow valve is accessible through a screw plug1 and can be adjusted from the outside Ä During operation,Page30.
6 Transportation, storage
6.1 Dangers during transportation
The following safety instructions must be observed:
o Have all work only carried out by authorized transport personnel.
o Use intact and correctly dimensioned hoisting equipment.
o Ensure that the means of transport is in a flawless state.
o Ensure that the centre of gravity of the load is taken into consideration.
o Do not stand under raised loads.
6.2 Dangers during storage
The following safety instructions must be observed:
o Observe the storage conditions.
6.3 Unpacking and checking the state of delivery
Personnel qualification: o Trained personnel
1. Upon delivery check the pump/pump unit for damage during transportation.
2. Report damage during transportation immediately to the manufacturer.
3. Dispose of packaging material in accordance with the locally applicable regulations.
Operating instructions
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17
6 Transportation, storage
6.4 Transporting the pump/pump unit
6.4 Transporting the pump/pump unit
Personnel qualification: o Crane operators, forklift operators
Personal protective equipment: o Work clothing
Aids: o Mobile crane, forklift
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
WARNING
o Transport personnel
o Protective helmet
o Protective gloves
o Safety boots
o Hoisting equipment
Risk of injury and damage to equipment through falling and toppling parts.
► Use intact and correctly dimensioned hoisting equipment in accordance with the total weight to be
transported.
► Select the lift points for the hoisting equipment in accordance with the centre of gravity and the
weight distribution.
► Use at least two load ropes.
► In the case of vertical transportation secure the motor against tippling.
► Do not stand under raised loads.
ATTENTION
Damage to equipment through improper transportation.
► Protect the pump against damage, heat, sunlight, dust and moisture.
18
Fig.6: Fastening of hoisting equipment - principle diagrams
1. Attach the hoisting equipment to the pump/pump unit and tighten. Ensure that the centre of gravity lies exactly under the crane hook.
2. Lift the pump/pump unit carefully and put it down shock-free.
3. Before loosening the transport belts ensure that the pump/pump unit is secured against tilting.
OIL 02en-GB Edition 2019-03
Operating instructions
7 Preservation
6.5 Storing the pump
6.5 Storing the pump
During the test run, the internal components of the pump are wetted with test oil, which has a preservative effect. Pressure connection and suction connection are closed with protective caps. Unless otherwise specified, the outer surfaces of the pump are preserved with a single-coat PU-based two-component paint.
The preservative applied at the factory will protect the pump for about six weeks, if it is stored in a dry
and clean location.
The manufacturer offers a long-term preservation for storage times of up to 60 months. The pump is
additionally packed in hermetically sealing anti-corrosion paper.
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
ATTENTION
Damage to equipment and corrosion if stored improperly and during longer standstills.
► Protect the pump against damage, heat, sunlight, dust and moisture.
► Protect against corrosion during longer standstill.
► Observe measures for storing and preservation.
1. Store cool and dry and protect against sunlight.
2. Ensure that the anti-corrosion paper is not damaged.
3. Observe the intervals for preservation Ä Preservation,Page19.
7 Preservation
7.1 Preservation table
Preservation has to be carried out additionally under the following conditions:
Type of delivery Condition
Standard delivery
Delivery with long-term preservation
Tab.10: Conditions for additional preservation
7.2 Preserving the inner surfaces
o Storage time exceeding six weeks
o Unfavourable storage conditions such as high humidity,
salty air, etc.
o Opened or damaged packaging
Operating instructions
Personnel qualification: o Trained personnel
Personal protective equipment: o Work clothing
o Protective gloves
o Safety boots
Aids: o Preservative (acid-free and resin-free oil)
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19
7 Preservation
7.3 Preserving the outer surfaces
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
1. Open the packaging carefully. If the pump is protected additionally by anti-corrosion paper, ensure that it is not damaged.
2. Close the suction connection of the pump with a blind flange.
3. Pour the preservative into the pressure connection until it reaches approx.2cm under the rim,
while slowly turning the main screw against the direction of rotation.
4. Close the pressure connection of the pump with a new blind flange.
5. Close the packaging carefully.
6. After about six months storage check the filling level of the preservative and if necessary top up.
7.3 Preserving the outer surfaces
Personnel qualification: o Trained personnel
Personal protective equipment: o Work clothing
Aids: o Castrol Rustilo DWX 33 or other preservative offering compar-
o Face protection
o Protective gloves
o Safety boots
able protection
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
1. Paint or spray the preservative onto all plain and unpainted parts.
2. At intervals of about six months check the preservation and if necessary repeat.
7.4 Removing the preservation
Personnel qualification: o Trained personnel
Personal protective equipment: o Work clothing
o Face protection
o Protective gloves
o Safety boots
Aids: o Solvent
o Collection tank
o Steam-jet cleaning device with wax-dissolving additives
DANGER
20
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
OIL 02en-GB Edition 2019-03
Operating instructions
8 Installation, removal
8.1 Dangers during installation
CAUTION
Risk of injury through emitted preservative.
► Wear personal protective clothing during all the work.
► Collect any discharging preservative safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
1. Clean the outside of the pump with solvents, if necessary using a steam-jet cleaning device.
2. Remove the pressure-side blind flange carefully in order to reduce any pressure that may exist in
the pump.
3. Drain the pump, collecting the preservative in a suitable vessel.
4. Remove the blind flange on the suction side.
5. To remove the residual preservative, flush the pump with the pumped liquid.
8 Installation, removal
8.1 Dangers during installation
The following safety instructions must be observed strictly:
o Have all work carried out only by authorized qualified personnel.
o Before installation ensure that the operating limits, NPSH values and ambient conditions are ob-
served.
o Observe the tightening torques Ä Appendix,Page55.
o Ensure that all the components can be accessed and that maintenance work can be carried out
easily.
8.2 Dangers during removal
The following safety instructions must be observed strictly:
o Have all work carried out only by authorized qualified personnel.
o Before beginning work, let the pump unit cool down to the ambient temperature.
o Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
o Ensure that the collection tank for discharging pumped liquids is sufficiently large.
8.3 Installing the pump
The pumps can be operated in horizontal and vertical installation position.
Notice Soiling in the pipe system impair the service life of the pump. If the pipe system is flushed using the
pump during the initial commissioning, an additional commissioning filter has to be installed temporarily
before the pump at the system (mesh width: 0.02mm).
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
Operating instructions
WARNING
Risk of injury and damage to equipment through falling and toppling parts.
► Only fasten the pump on a stable load-bearing underground or stable load-bearing load support.
► Ensure that fastening elements and pipings are fastened sufficiently.
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21
8 Installation, removal
1
2
8.4 Removing the pump
ATTENTION
Damage to motor through emitted pumped liquid.
► Do not install the pump above the motor.
ATTENTION
Damage to device through impurity in the pipe system.
► During welding work attach protective covers in front of the connecting flanges.
► Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and
the pump.
► Ensure that a commissioning filter is installed when the pipe system is flushed and cleaned using
the pump.
1 Pressure connection
2 Suction connection
Fig.7: Flow direction
Requirement:
ü Pump connections protected against soiling, for example by using the protective cover mounted in
the factory
ü If required, hoisting equipment prepared
1. Bring the pump in the installation position, while observing the position of the motor and the arrows for the flow direction on the pump housing (1pressure connection, 2suction connection).
2. Fasten the pump with fastening elements securely on the underground.
8.4 Removing the pump
Personnel qualification: o Fitter
o Electrician
o Crane operators, forklift operators
Personal protective equipment: o Work clothing
o Protective helmet
o Face protection
o Protective gloves
o Safety boots
Aids: o Mobile crane, forklift
o Hoisting equipment
o Collection tank
DANGER
22
Risk of death resulting from electric shock.
► Ensure that the electrical power supply is de-energized and is secured against being switched
back on.
► Observe the operating instructions of the electrical components.
OIL 02en-GB Edition 2019-03
Operating instructions
9 Connection
9.1 Dangers during connection work
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
DANGER
Risk of death through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible and caustic and can spray out under high pressure.
► Wear personal protective clothing during all the work. Ensure face protection.
► Before beginning work, let the pump unit cool down to the ambient temperature.
► Ensure that the pump is depressurized.
► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
Requirement:
ü Pump unit cooled down to the ambient temperature
1. Close the pressure-side and suction-side shut-off devices.
2. Empty the pump at the lowest point. Collect the discharging pumped liquid in a collection tank.
3. Dismantle the pressure-side and suction-side connecting flange
4. Disconnection the pump unit from the pipe system and empty it. Collect any discharging pumped
liquid.
5. Screw out the fastening elements used to fasten the pump.
6. Dismantle the pump unit on site or transport it to a suitable location Ä Transportation, storage,Page17.
9 Connection
9.1 Dangers during connection work
The following safety instructions must be observed strictly:
o Have all work on the pump and pipe system only carried out by authorized qualified personnel.
o Ensure that impurities cannot get into the pump and pipe system.
o Ensure that mechanical connections are mounted stress-free.
o Observe the tightening torques Ä Appendix,Page55.
o Have all the work on the electrical equipment only carried out by electricians.
o Before beginning work on the pump ensure that the electrical power supply is deenergized and is
secured against being switched back on.
o If the insulation of the electrical cables or wires is damaged, disconnect the power supply immedi-
ately.
Operating instructions
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23
9 Connection
9.2 Connecting the pump to the pipe system
9.2 Connecting the pump to the pipe system
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
Aids: o Mobile crane, forklift
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
ATTENTION
o Protective gloves
o Protective helmet
o Safety boots
o Hoisting equipment
Damage to device through impurity in the pipe system.
► During welding work attach protective covers in front of the connecting flanges.
► Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and
the pump.
► Ensure that a commissioning filter is installed when the pipe system is flushed and cleaned using
the pump.
ATTENTION
Damage to device through mechanical stress.
► Ensure that the pump is mounted free of mechanical stresses in the pipe system.
► Observe the tightening torques.
Fig.8: Connection to pipe system
1. Turn the pump shaft or the fan impeller of the motor. This tests that the pump runs smoothly.
If the pump shaft cannot be turned by hand, remedy the fault before installing the pump Ä
Troubleshooting,Page45.
2. Before carrying out welding work mount a protective cover on the suction connection and pressure connection.
3. Place the piping in position and support the weight of the piping.
4. Check the linear, height and angular offset and correct if necessary.
ð If the screws tighten easily, this is a sure sign that the installation is stress-free.
5. Tighten the connecting screws crosswise with torque, Table of tightening torques Ä Appendix,Page55.
24
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Operating instructions
9.3 Connecting the pump unit to the power supply
9.3 Connecting the pump unit to the power supply
Personnel qualification: o Electrician
Aids: o Operating instructions of the motor
o Motor circuit diagram
DANGER
Risk of death resulting from electric shock.
► Ensure that the electrical power supply is de-energized and is secured against being switched
back on.
► Before commissioning ensure correct grounding and equipotential bonding.
► Observe the operating instructions of the electrical components.
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
10 Operation
1. Ensure that the operating data on the rating plate of the motor agree with the operating data of
the pump and with the local power supply.
2. Connect the motor in accordance with the operating instructions and circuit diagram in the motor
terminal block.
10 Operation
10.1 Dangers during operation
The following safety instructions must be observed strictly:
o Have all work carried out only by authorized qualified personnel.
o Before commissioning ensure that a safety valve has been installed in the pipe system on the
pressure side before the first shut-off device.
o Before commissioning, make sure that the suction line and pump are filled.
o Pumped liquids can be hot, poisonous, combustible and caustic. Use corresponding protective
equipment.
o Ensure that the pump station is only operated within the operating limits.
o During a standstill ensure that the pressure in the pump does not exceed the inlet pressure.
o Ensure that during cooling down or heating up the pump is only subjected to slow temperature
changes.
o Ensure that existing safety equipment is not bypassed or activated during operation.
o Before decommissioning ensure that the electrical power supply is deenergized and is secured
against being switched back on.
Operating instructions
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25
10 Operation
10.2 Commissioning
10.2.1 Cleaning the pipe system
Notice Soiling in the pipe system impair the service life of the pump. If the pipe system is flushed using the
10.2 Commissioning
pump during the initial commissioning, an additional commissioning filter has to be installed temporarily
before the pump at the system.
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
o Protective gloves
o Safety boots
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump station.
ATTENTION
Damage to equipment through additional pressure loss in the commissioning filter/commissioning strainer.
► Calculate the flow resistance and determine the remaining pump intake.
► Monitor the suction-side pressure.
► Check the commissioning filter/commissioning strainer regularly.
Requirement:
ü If required, commissioning filter installed (mesh width0.02 mm)
1. Clean the complete pipe system before commissioning in order to protect the pump.
2. Flush the pipe system at least 50 – 100hours.
10.2.2 Filling and venting the pump
Possibilities
There are two possible ways to fill the pump:
o Via the suction connection or pressure connection
o Via the vent holes
Filling and venting the pump via the suction connection or pressure connection
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
o Protective helmet
o Face protection
o Protective gloves
o Safety boots
26
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
OIL 02en-GB Edition 2019-03
Operating instructions
10 Operation
2
1 3
10.2 Commissioning
DANGER
Risk of death through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible and caustic and can spray out under high pressure.
► Wear personal protective equipment during all the work. Ensure face protection.
► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
1 Pressure connection
2 Seal housing vent hole
3 Suction connection
1. Open the screw plug of the vent hole seal housing2 by a max.of two rotations so that air can escape during the filling process.
2. Open the suction-side or pressure-side shut-off device and fill the pump via the suction connection1 or pressure connection3 until pumped liquid is emitted at the vent hole seal housing.
3. Retighten the screw plug of the vent hole seal housing.
Filling and venting the pump via the vent hole
Notice Filling the pump via the vent hole only makes sense in the horizontal mounting position.
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
o Protective helmet
o Face protection
o Protective gloves
o Safety boots
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
WARNING
Risk of injury through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible and caustic.
► Wear personal protective clothing during all the work. Ensure face protection.
► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
Operating instructions
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27
10 Operation
1
2
3
4
5
1
10.2 Commissioning
10.2.3 Checking the direction of rotation
Notice Standard direction of rotation: clockwise (viewed from the motor)
1 Suction connection
2 Seal housing vent hole
3 Pressure-side vent hole
4 Pressure connection
5 Suction-side vent hole
Fig.9: Vent holes
Requirement:
ü Shut-off devices of the suction line and pressure line closed
1. Open the screw plug of the vent hole seal housing2 by a max.of two rotations so that air can escape during the filling process.
2. Remove the screw plug of the vent hole suction-side5 or vent hole pressure-side3.
3. Fill the pump via the vent hole suction-side or the vent hole pressure-side until the pumped liquid
is emitted at the vent hole seal housing.
4. Retighten the screw plug of the vent hole seal housing and the vent hole suction-side or vent hole
pressure-side.
The direction of rotation is indicated by an arrow on the pump flange. The direction of rotation of the
motor specifies the direction of rotation of the pump. The fan impeller of the motor must rotate in the
same direction in which the arrow for the direction of rotation on the pump flange points.
Personnel qualification: o Fitter
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
ATTENTION
Dry running can damage pump equipment.
► Ensure that the pump is filled properly.
► Switch the pump on for a maximum of one second and then off again immediately.
1. Switch on the power supply and then turn it off again immediately.
2. Compare the direction of rotation of the fan impeller with the arrow indicating the direction of rotation1.
3. If the directions do not match, swap the two electrical connection phases. Repeat Steps1 and2.
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Operating instructions
10.2.4 Commissioning the pump
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
Aids: o Collection tank
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
DANGER
10 Operation
10.2 Commissioning
o Electrician
o Face protection
o Protective gloves
o Safety boots
Risk of death resulting from bursting components and emitted pumped liquid.
As a result of impermissibly high pressure, components can burst with high energy, for example
through the pressure-side pipe system being shut off.
► Wear personal protective equipment during all the work.
► Before carrying out commissioning ensure that a safety valve is installed in the pressure-side pipe
system at the system end.
WARNING
Hot surface.
Touching of uninsulated hot surfaces results in burns.
► Insulate components and pipings in which hot liquids flow before commissioning.
WARNING
Risk of injury through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible and caustic.
► Wear personal protective clothing during all the work. Ensure face protection.
► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
Operating instructions
ATTENTION
Dry running can damage pump equipment.
► Ensure that the pump and the connected pipe system are filled properly.
► If the pump does not deliver after10–15 seconds, abort commissioning.
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29
10 Operation
barbar
10.3 During operation
10.3 During operation
Requirement:
ü Pump unit set up correctly
ü Connections connected sealingly
ü Motor connected correctly
ü Pipe system is free of impurities
ü Safety valve in accordance with ENISO4126-1 installed in the pressure-side pipe system before
the first shut-off device
ü Pump filled with pumped liquid
ü Shut-off devices in the suction line and pressure line opened
1. Switch on the pump unit.
ð The pump delivers when the pressure on the pressure side of the pump rises or a flow indic-
ator at the system side triggers.
2. If the pump does not deliver after10–15seconds of operation, abort commissioning. Eliminate
the cause for the fault and only then continue with commissioning. Take the information from the
fault table into account Ä Troubleshooting,Page45.
3. Run the pump for a few minutes to allow the pipe system to vent fully.
ð The pipe system is fully vented when there is a smooth operating noise and a pressure gauge
on the pressure side of the pump shows no more fluctuations.
10.3.1 Checking the operating pressure
Personnel qualification: o Trained personnel
Fig.10: Pressure gauge shut-off valves closed/open - principle diagram
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump station.
ATTENTION
Leak in the pressure gauge through permanently opened pressure gauge shut-off valve.
► Close the pressure gauge shut-off valve immediately after completing reading.
30
1. Open the pressure gauge shut-off valve.
2. Read the operating pressure and close the pressure gauge shut-off valve.
OIL 02en-GB Edition 2019-03
Operating instructions
10 Operation
2
3
1
4
10.3 During operation
10.3.2 Monitoring filters and/or strainers
Notice The manufacturer recommends protecting the pump against soiling by means of a filter and/or strainer
installed at the system end (mesh width 0.5mm). The degree of soiling of the filter and/or the strainer
can be monitored by means of a suction-side pressure gauge or a differential pressure indicator.
Personnel qualification: o Trained personnel
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump station.
1. After commissioning monitor the degree of contamination of the filter and/or strainer by means of
a suction-side pressure gauge or a differential pressure indication.
2. Additionally check the filters and/or strainers at a pressure drop on the suction side. Observe the
dimensioning data of the manufacturer of the filters/strainers.
3. Check the suction-side pressure every two weeks during running operation.
10.3.3 Adjusting the overflow valve
Personnel qualification: o Fitter
Aids: o Hexagon key
Notice The opening pressure of the overflow valve is set to 110% of the differential pressure in the factory.
1 Screw plug
2 Adjusting screw
3 Pressure spring
4 Valve body
Fig.11: Overflow valve
WARNING
Risk of injury through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible and caustic.
► Wear personal protective clothing during all the work. Ensure face protection.
► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
Requirement:
ü Pressure-side pressure gauge installed
1. Switch on the pump and remove the screw plug 1 of the overflow valve.
2. Increase the supply pressure step-by-step to check the opening pressure of the overflow valve.
Keep an eye on the pressure gauge and make sure that the operating limits are observed.
ð The opening pressure is reached, when the displayed pressure falls.
3. Turn the adjusting screw2 to set the opening pressure:
Turning clockwise: Increase the opening pressure
Turning counter-clockwise: Reduce the opening pressure
4. Repeat Steps 2 and 3 until the desired opening pressure is reached.
5. Tighten the screw plug1 again.
Operating instructions
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31
10 Operation
10.4 Decommissioning
10.3.4 Switching off the pump unit
10.4 Decommissioning
10.4.1 Decommissioning the pump
Personnel qualification: o Trained personnel
ATTENTION
Seal damage through pressurizing during standstill.
► During a standstill ensure that the pressure in the pump does not exceed the feed pressure.
1. Switch off the motor.
2. Close the pressure- and suction-side shut-off devices.
Decommissioning is an operation interruption that requires different measures depending on the scope
of duration and the interruption as well as the properties of the pumped liquid.
Personnel qualification: o Fitter
o Electrician
Personal protective equipment: o Work clothing
o Protective gloves
o Safety boots
Aids: o Collection tank
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
WARNING
Risk of injury through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible and caustic.
► Wear personal protective clothing during all the work. Ensure face protection.
► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
ATTENTION
Damage to equipment through excessively fast temperature change.
► Subject the pump only to slow temperature changes.
► Under no circumstances heat the pump with an open flame.
32
OIL 02en-GB Edition 2019-03
Operating instructions
11 Maintenance
10.5 Recommissioning
Carry out the following measures during operation interruptions:
Scope of the operation interruption Measure
o Shutting down the pump for longer period Depending on the pumped liquid
o Draining the pump Close the pressure-side and suction-side
shut-off devices.
o Dismantling the pump Disconnect the motors from the power sup-
ply and secure against being switched back
on.
o Storing the pump Observe measures for storing and preserva-
tion Ä Transportation, storage,Page17.
Tab.11: Measures during operation interruptions
Behaviour of the pumped liquid
o Solids sediment Rinse the pump. Rinse the pump.
o Congealed/frozen
o No corrosive burden
o Congealed/frozen
o Corrosive burden
o Remains liquid
o No corrosive burden
o Remains liquid
o Corrosive burden
Tab.12: Measures depending on the behaviour of the pumped liquid
Drain the pump via the pressure line, suction line, vent screws and screw plugs.
10.5 Recommissioning
10.5.1 Recommissioning the pump
Carry out all the steps as for the commissioning process, Ä Commissioning,Page26.
11 Maintenance
Duration of the operation interruption
Short Long
Heat or drain the pump. Drain the pump.
Heat or drain the pump. 1. Drain the pump.
2. Preserve the pump.
– –
–
1. Drain the pump.
2. Preserve the pump.
Operating instructions
11.1 Dangers during maintenance
The following safety instructions must be observed strictly:
o Have all work carried out only by authorized qualified personnel.
o Before beginning work, let the pump unit cool down slowly to the ambient temperature. Avoid
rapid temperature changes.
o Pumped liquids can be hot, poisonous, combustible and caustic. Use corresponding protective
equipment.
o Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
o Ensure that the collection tank for discharging pumped liquids is sufficiently large.
o Observe the operating instructions and data sheets of the components.
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33
11 Maintenance
11.2 Required maintenance
11.2 Required maintenance
The service life depends on the observance of the operating conditions of the pump and the requirements from the operating instructions of the components.
Component Required maintenance Cycle
Pump
Filter/strainer (at the system side)
Tab.13: Required maintenance
11.3 Ball bearing
The ball bearings used are lubricated by the pumped liquid. Maintenance is therefore not required. The
manufacturer recommends renewing the ball bearings every 20,000 operating hours.
11.4 Maintaining the pump
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
o Visual inspection
o Acoustic inspection
o Check the suction-side pres-
sure
o Protective gloves
o Safety boots
o Face protection
4weeks
2weeks
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
WARNING
Risk of injury through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible and caustic.
► Wear personal protective clothing during all the work. Ensure face protection.
► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
1. Check the pump visually and acoustically every four weeks.
2. If there are signs of wear, eliminate the cause Ä Servicing,Page35.
11.5 Maintaining the magnetic coupling
Personnel qualification: o Fitter
34
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
OIL 02en-GB Edition 2019-03
Operating instructions
12 Servicing
914.7
917**
914.6
914.5
884**
585
12.1 Dangers during servicing
Check the tightening torques of the following parts of the magnetic coupling once a year. Repla-
cing the magnetic coupling Ä Servicing,Page35. Tightening torques Ä Appendix,Page55.
Item No. Part
585 Tensioning element
884** Threaded pin outer rotor support
914.5 Socket screws pump bracket– pump
914.6 Socket screws outer rotor support– outer rotor
914.7 Socket screws containment can– pump
917** Countersunk screw outer rotor support
** Depending on motor size
Tab.14: Magnetic coupling: Parts to be maintained
12 Servicing
12.1 Dangers during servicing
The following safety instructions must be observed strictly:
o Have all work carried out only by authorized qualified personnel.
o Before beginning work on the pump ensure that the electrical power supply is deenergized and is
secured against being switched back on.
o Before beginning work, let the pump unit cool down slowly to the ambient temperature. Avoid
rapid temperature changes.
o Pumped liquids can be hot, poisonous, combustible and caustic. Use corresponding protective
equipment.
o Ensure that the pump is depressurized and that shut-off devices are not operated uncontrolled.
o Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
o Ensure that the collection tank for discharging pumped liquids is sufficiently large.
o Observe the tightening torques Ä Appendix,Page55.
o Observe the operating instructions and data sheets of the components.
12.2 Wear
12.2.1 Magnetic coupling
If the pump is operated properly and as specified, maintenance of the magnetic coupling is not required
during its complete operating life.
The manufacturer recommends an inspection of the magnetic coupling during the plant revision, at the
latest after 2.5 years.
Operating instructions
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35
12 Servicing
164
222
914.1
501
305 1
165.1
2
164
222
914.1
501
305 1
165.1
2
12.3 Replacing the overflow valve
12.3 Replacing the overflow valve
12.3.1 Removing the overflow valve
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
1. Remove the screw plug165.1 and socket screws914.1.
2. Remove the end cover2 and flat gasket222 from the pump housing1.
3. Screw out the adjusting screw164 and remove the pressure spring501 and valve body305 from
the pump housing.
o Protective gloves
o Safety boots
12.3.2 Installing the overflow valve
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
1. Clean the fitting surface carefully and bond a new flat gasket222 to the fitting surface.
2. Insert the valve body305, pressure spring501 into the pump housing1 and secure the pressure
spring with the adjusting screw164.
3. Position the end cover2 and tighten the socket screws914.1 with torque.
4. Set the overflow valve Ä During operation,Page30.
o Protective gloves
o Safety boots
36
Operating instructions
OIL 02en-GB Edition 2019-03
12.4 Replacing the magnetic coupling
1
180
2
914.3
917**
052
884**
515
515
052
2
884** 917**
12.4.1 Removing the outer rotor
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
Aids: o Open-end spanner
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
12 Servicing
12.4 Replacing the magnetic coupling
o Protective gloves
o Safety boots
o Mounting lever
o Hoisting equipment
WARNING
Risk of injury and damage to equipment through falling and toppling parts.
► Use intact and correctly dimensioned hoisting equipment in accordance with the total weight to be
transported.
► Select the lift points for the hoisting equipment in accordance with the centre of gravity and the
weight distribution.
► Use at least two load ropes.
► In the case of vertical transportation secure the motor against tippling.
► Do not stand under raised loads.
Notice Outer rotor support and outer rotor can be dismantled more easily if they are heated to 80°C.
Requirement:
1. Before dismantling close the suction connection and pressure connection of the pump with protective covers.
2. Fixate the pump unit with suitable measures.
3. Attach the hoisting equipment to the motor2.
4. Loosen the socket screws914.3 between the motor and the pump bracket180.
5. Lift the motor off the pump bracket.
Operating instructions
6. Depending on the motor size, remove the threaded pin884** from the outer rotor support052 or
the countersunk screw917** from the outer rotor515.
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37
12 Servicing
515
052
515
914.6
052
180
914.5
914.7
038
518
1
518
585
M
12.4 Replacing the magnetic coupling
7. Pull the outer rotor support and the outer rotor off from the motor shaft using mounting levers.
8. Remove the socket screws914.6 between the outer rotor support and the outer rotor.
12.4.2 Removing the inner rotor
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
Aids: o Hexagon key
o Protective gloves
o Safety boots
o Anti-rotation screw
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
Notice The containment can be dismantled more easily if it is heated to 80°C.
1. Remove the socket screws914.5 between the pump1 and pump bracket180 and remove the
pump bracket.
2. Remove the socket screws914.7 between the containment can038 and the pump and remove
the containment can.
38
OIL 02en-GB Edition 2019-03
Operating instructions
3. To replace the inner rotor518, screw two screwsM into the empty threaded holes of the tension-
585
518
518
040
739
585
518
040
ing element585 as anti-rotation screws.
4. Remove the screws of the tensioning element.
5. Turn the screws back into the existing threaded holes.
ð This loosens the tensioning element from the inner rotor and from the pump shaft.
12.4.3 Installing the inner rotor
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
Aids: o Oil without molybdenum sulphide additive (e.g. multifunction
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
12 Servicing
12.4 Replacing the magnetic coupling
o Protective gloves
o Safety boots
spray WD-40)
Notice The inner rotor can be mounted more easily if it is heated to 80°C.
1. Carefully clean the contact surfaces of the inner rotor518, oil the tensioning element585 lightly.
2. Manually turn out the screws of the tensioning element by a few turns and insert the tensioning
element in the inner rotor.
3. Carefully clean the sealing surfaces.
4. Clean and lightly grease the O-ring739. Insert the O-ring and slide the distance sleeve040 onto
the pump shaft.
Operating instructions
5. Place the inner rotor with the premounted tensioning element onto the pump shaft and tighten the
screws of the tensioning element crosswise by hand.
6. Check the position of the tensioning element: The tensioning element has to lie flat on the distance sleeve and inner rotor. Otherwise loosen the screws and reposition the tensioning element.
OIL 02en-GB Edition 2019-03
39
12 Servicing
180
914.5
914.7
038
518
1
515
914.6
052
12.4 Replacing the magnetic coupling
7. When the position is correct, first tighten the screws of the tensioning element with half the torque
crosswise. Subsequently tighten several times crosswise with the full torque.
ð The screws are tightened correctly when they no longer turn when being tightened with the full
torque.
8. Press the containment can038 onto the pump flange and tighten with socket screws914.7 using
torque.
9. Place the pump bracket180 on the pump and tighten the socket screws914.5 with torque.
12.4.4 Installing the outer rotor
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
Aids: o Hoisting equipment
o Protective gloves
o Safety boots
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
WARNING
Danger of crushing when assembling motor and pump.
When the motor approaches the pump, high magnetic forces can produce sudden collisions and thus
injuries to hands or fingers.
► Two persons are required for the assembly.
► Use suitable hoisting equipment (for example chain hoist).
► Carry out assembly in the vertical position as far as possible.
► Fixate the pump with suitable measures.
► When the motor approaches the pump, ensure that hands/fingers are not positioned between mo-
tor and pump.
Notice Outer rotor support and outer rotor can be installed more easily if they are heated to 80°C.
40
1. Carefully clean the outer rotor515 with compressed air. Tighten the socket screws914.6
between the outer rotor and outer rotor support052 with torque Ä Appendix,Page55.
OIL 02en-GB Edition 2019-03
Operating instructions
12 Servicing
515
052
2
917**
052
884**
515
515
052
2
884** 917**
1
180
515
2
914.3
12.4 Replacing the magnetic coupling
2. Clean and grease the shaft end of the motor2.
3. Place the outer rotor support052 with the outer rotor515 on the shaft end of the motor.
4. Ensure that the shaft end of the motor2 is flush with the front surface of the outer rotor support052.
5. Depending on the motor size tighten the threaded pin884** or the countersunk screw917**.
6. Attach the hoisting equipment to the motor2 and position it above the pump1.
7. Place the motor on the pump bracket180 of the pump. Do not use force in the process and ensure that the outer rotor515 does not strike the containment can.
8. Tighten the socket screws914.3 with torque.
9. Do not remove the protective cover until just before reconnecting the pump to the pipe system.
Operating instructions
OIL 02en-GB Edition 2019-03
41
12 Servicing
914.2
661.1
131
080
471.1
661.1
055.1
080
472
055.2*
817
080
N
055.2*
042
661.1
471.2
12.5 Replacing the ball bearing and screw set
12.5 Replacing the ball bearing and screw set
12.5.1 Removing the ball bearing and screw set
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
Aids: o Plastic hammer
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
o Protective gloves
o Safety boots
o Extractor
1. Remove the socket screws914.2 and screw two forcing screws into the bearing cover080.
ð The bearing cover is pressed out of the pump housing131 together with the main
screw661.1.
2. Pull the bearing cover out of the pump housing together with the main screw.
3. Remove the circlips471.1 and472 as well as the supporting ring055.1.
4. Drive the main screw out of the bearing cover with light blows from a plastic hammer.
5. Size5–26 and55–85: Remove the supporting ring055.2*.
6. Pull the ball bearing817 out of the bearing cover using a suitable extractorN.
42
7. Remove the circlip471.2 and balancing cylinder042.
OIL 02en-GB Edition 2019-03
Operating instructions
914.1
070
879.2
661.2
222
048
131
8. Remove the socket screws914.1 and end cover070.
914.1
070
879.2
661.2
222
048
131
042
661.1
471.2
471.1
661.1
055.1
080
472
055.2*
9. Remove the balancing bushes048 with straight pin879.2 and idle screws661.2 from the pump
housing.
10. Remove the residues of the flat gasket222 from the end cover and pump housing.
12.5.2 Installing the ball bearing and screw set
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
o Protective gloves
o Safety boots
Aids: o Mounting sleeve ball bearing
12 Servicing
12.5 Replacing the ball bearing and screw set
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
1. Clean the fitting surfaces, clean and grease the screw set carefully.
2. Insert the idle screws661.2 in the pump housing131.
3. Mount the balancing bushes048 and straight pin879.2.
4. Bond the new flat gasket222 on the pump housing.
5. Place on the end cover070 and tighten the socket screws914.1 with torque Ä Appendix,Page55.
Operating instructions
6. Press the balancing cylinder042 onto the main screw661.2 and mount the circlip471.2.
7. Size5–26 and55–85: Mount the supporting ring055.2.
8. Slide the main screw661.1 into the bearing cover080, mount the circlip471.1 and supporting
ring055.1.
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43
13 Disposal
472
817080
914.2
661.1
131
080
13.1 Dismantling and disposing of the pump
9. Press the ball bearing817 into the bearing cover and mount the circlip472.
10. Slide the main screw with premounted bearing cover into the pump housing until the main screw
engages into the idle screws. Turn the main screw in the process.
11. Tighten the socket screws914.2 with torque Ä Appendix,Page55.
13 Disposal
13.1 Dismantling and disposing of the pump
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
o Face protection
o Protective gloves
o Safety boots
Aids: o Solvents or industrial cleaners suitable for the pumped liquid
o Collection tank
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
WARNING
Danger of poisoning and environmental damage through residues.
► Wear personal protective clothing during all the work. Ensure face protection.
► Before disposal collect any pumped liquid still present safely and dispose of it in an environment-
ally compatible manner in accordance with the applicable local regulations.
► Before disposing neutralize the residues.
Requirement:
ü Disconnect the pump unit from the power supply and secure it against being switched back on
ü Pump unit cooled down to the ambient temperature and disconnected from the pipe system
ü Pump emptied completely
ü Pump placed at a location suitable for dismantling
1. Dismantle the pump and disassemble it into its individual parts.
2. Clean residues of the pumped liquid from the individual parts.
3. Separate sealing elements made of elastomers and ceramics (SiC) from the pump and dispose
of them in separately.
44
4. Recycle iron parts.
OIL 02en-GB Edition 2019-03
Operating instructions
14 Troubleshooting
14.1 Possible faults
14 Troubleshooting
14.1 Possible faults
Faults can have different causes. The following tables list the symptoms of a fault, the possible causes
and measures for troubleshooting.
Identification
1 No pump suction
2 Delivery rate too low
3 Pump too loud
4 Motor overload
5 Uneven delivery rate
6 Pump has seized
7 Magnetic coupling leaks
Fault
14.2 Troubleshooting
Fault identification Cause Remedy
1 – – – – – – Pump suction line closed
Check the shut-off devices. If required, open.
1 2 3 – 5 – – Parts soiled (filter, suction line, suction valve, strainer)
Clean parts.
1 2 3 – 5 – – Suction head too high
Reduce the level difference.
-orReduce the line length.
-orIncrease the line cross-section.
-orHeat up the pumped liquid.
-orInstall a filter / strainer with a larger mesh width. Ensure that the permissible mesh width
is not exceeded.
1 – 3 – – – – Level in the intake container too low
Fill the intake container.
1 – – – – – – Too little pumped liquid in the pump
Fill the pump with pumped liquid.
1 – – – – – – Incorrect pump direction of rotation
Swop the two electrical connection phases Ä Connection,Page23.
– – – 4 – – – Differential pressure too high
Reduce the differential pressure.
1 – 3 4 5 – – Viscosity of the pumped liquid too high
Increase the temperature of the pumped liquid.
-orDecrease the speed.
– 2 – – – – – Viscosity of the pumped liquid too low
Reduce the temperature of the pumped liquid.
-orIncrease the speed.
– 2 3 – 5 – – Airlock/gas in the pumped liquid
1. Test the pipe system for air admission, replace leaking parts.
2. Reduce the suction head.
-orIncrease the inlet pressure.
Operating instructions
OIL 02en-GB Edition 2019-03
45
14 Troubleshooting
14.2 Troubleshooting
Fault identification Cause Remedy
– 2 – 4 – – – Speed/frequency/voltage of the motor false
1. Ensure that the motor frequency and voltage match the operating voltage.
2. Ensure that the speed of the motor matches the rating plate of the pump. If necessary adjust the speed.
– 2 3 – 5 – – Overflow valve opens during normal operation
Set the opening pressure to 110% of the differential pressure Ä During opera-
tion,Page30.
– 2 – – 5 – – Overflow valve leaks
Contact the manufacturer.
– 2 – – – – – Advanced wear of the housing/screw set
Contact the manufacturer.
– – 3 – – – – Pump subject to mechanical stress
Connect the pump correctly to the pipe system Ä Connection,Page23.
– – 3 – – – – Vibrations/pulsations in the system
Bear the pump unit elastically.
-orMake the connections with hoses.
– – 3 – – – – Flow speed in the pressure line or suction line too high
Set the flow speed in the pressure line so that it does not exceed 3m/s.
-orSet the flow speed in the suction line so that it does not exceed 1m/s.
-orContact the manufacturer.
– – 3 4 – – 7 Ball bearing damaged
Replace the ball bearing Ä Servicing,Page35.
– – – 4 – – 7 Foreign bodies in the pump
Contact the manufacturer.
– – – – – – 7 Differential pressure is too high and has overloaded the idle screws
Contact the manufacturer.
– – – – – – 7 Viscosity is too low and has overloaded the idle screws
Contact the manufacturer.
1 2 3 4 – – 7 Pump damaged through dry running
Contact the manufacturer.
1 – – – – – – Pump does not vent
Vent the pressure line at the highest point.
– 2 3 – – – – Magnetic coupling interrupted
1. Stop the pump immediately and restart it.
2. Avoid excessive differential pressures.
3. At repeated occurrence check whether pump has got stuck.
1 – – – – – 7 Containment can defective
Replace the containment can Ä Servicing,Page35.
Tab.15: Fault table
46
OIL 02en-GB Edition 2019-03
Operating instructions
15 Accessories
072
481
1
15.1 Heating
15.1.1 Possible types of heating
The pump can optionally be equipped with a heating system. The manufacturer recommends a heating
system at high-viscosity pumped liquids that do not flow sufficiently if not heated. This can result in excessive wattage or in problems arising through cavitation or sealing.
Possible types of heating:
o Electrical heating system
o Fluid heating system
o Special heating system
15.1.2 Electrical heating system
Fig.12: Electrical heating system
The electrical heating system consists of a heating element481 that is integrated in a heating
cover072 attached additionally to the end cover. The output of the heating element corresponds to the
radiation losses and convection losses of the pump in the required temperature range so that overheating is not possible.
15 Accessories
15.1 Heating
072 Heating cover
481 Heating element
1 Connecting cable
Size5–85
1 heating element
1 heating cover
4 socket screws
Tab.16: Scope of delivery of electrical heating system
Operating data
Parameter Unit Value
Voltage [V] 230
Frequency [Hz] 50/60
Wire cross-section [mm2] 2 x 1
Tab.17: Operating data electrical heating system
Heating-up period
Required heating-up period for temperature differences of 30°C or 50°C:
Size Wattage Heating-up period [min] at a temperature differ-
ence of
[W] 30°C 50°C
5–54 1 x 100 20 35
55–85 1 x 220 20 35
Tab.18: Heating-up period for electric heating system
Operating instructions
OIL 02en-GB Edition 2019-03
47
15 Accessories
072
481
1
15.1 Heating
Installing the electrical heating system
Personnel qualification: o Electrician
Personal protective equipment: o Work clothing
o Protective gloves
o Safety boots
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
ATTENTION
Damage to the electrical heating system through leakage currents or flashovers at the emission
point of the connecting cable.
► Protect the area of the connecting head against liquid and pasty liquids (lubricants, oil, plastics,
etc.) as well as their vapours.
Requirement:
ü Area of the connecting head protected against liquid and pasty liquids (lubricants, oil, plastics, etc.)
as well as their vapours.
ü Supply lines protected against mechanical vibrations in the area of the emission from the heating
element. Any vapours arising have to escape freely.
ü Heating element absolutely dry.
072 Heating cover
481 Heating element
1 Connecting cable
1. Remove the socket screws and rating plate at the end cover of the pump.
2. Mount the heating cover072 to the end cover using the supplied socket screws.
3. Screw the heating element481 into the heating cover.
4. Mount the rating plate on the heating cover.
Connecting the electrical heating system
DANGER
Risk of death resulting from electric shock.
► Ensure that the electrical power supply is de-energized and is secured against being switched
back on.
► Observe the operating instructions of the electrical components.
48
Connect the connecting cable of the heating element.
Commissioning the electrical heating system
1. Switch on the electric heating system.
2. Take the required heating-up periods into account Ä Accessories,Page47.
OIL 02en-GB Edition 2019-03
Operating instructions
15.1.3 Fluid heating system
072
1
1
072
1
1
Fig.13: Fluid heating system
The fluid heating system consists of a heating cover 072 attached additionally to the end cover through
which a heating fluid (for example vapour, thermal oil) flows.
Scope of delivery:
Size5–85
1 heating cover
4 socket screws
Tab.19: Scope of delivery of the fluid heating system
Heating liquid operating data
Parameter Unit Value
Max. operating overpressure [bar] 16
Max. temperature [°C] 200
Tab.20: Heating liquid operating data
15 Accessories
15.1 Heating
072 Heating cover
1 Pipe connection
Heating-up period
Required heating-up period for the temperature difference of 50°C at a liquid temperature of 200°C:
Size Heating-up period [min] at a temperature difference of 50°C
5–54 20
55–85 20
Tab.21: Heating-up period for fluid heating system
Installing the fluid heating system
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
o Protective gloves
o Safety boots
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
072 Heating cover
1 Pipe connection
Operating instructions
1. Remove the socket screws and rating plate at the end cover of the pump.
2. Mount the heating cover072 to the end cover using the supplied socket screws.
3. Mount the piping at the pipe connections1.
4. Mount the rating plate on the heating cover.
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16 Spare parts
16.1 Overview
Commissioning the fluid heating system
1. Take the required heating-up periods into account Ä Accessories,Page47.
2. When setting the pressure and temperature of the heating fluid take the permissible operating
limits of the pump into account Ä Technical data,Page11.
15.1.4 Heating system special design
Please contact the manufacturer for special designs.
16 Spare parts
16.1 Overview
Model/Size Type Variant Internal
LFI/LVI/LFT/
LVT/LFM
LFI/LVI/LFT/
LVT/LFM
LFI/LVI/LFT/
LVT/LFM
LFI/LVI/LFT/
LVT/LFM
LFI/LVI/LFT/
LVT/LFM
Tab.22: Overview of spare parts
Maintenance kit Magnetic coupling OPW39
Repair kit Screw set OPR07
Repair kit Overflow valve OPR08
Repair kit Magnetic coupling OPR10
Spare parts Completion ULF
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16.2 Maintenance kits
914.8***
471.1
055.1
817
914.2
729.2
165.2
165.2
472
055.2*
739
165.3
165.2
165.2
729.1
165.1
914.1
222
879.2
16.2 Maintenance kits
16.2.1 Maintenance kit magnetic coupling
Notice The maintenance kit contains only the numbered parts and is only supplied complete.
16 Spare parts
Qty. Item No. Part Qty. Item No. Part
1 055.1 Supporting ring 1 729.1 Flat gasket, suction flange
1 055.2* Supporting ring 1 729.2 Flat gasket, pressure flange
1 165.1 Screw plug 1 739 O-ring
4 165.2 Screw plug 1 817 Ball bearing
1 165.3 Screw plug 1 879.2 Straight pin
1 222 Flat gasket 4 914.1 Socket screw
1 471.1 Circlip 4 914.2 Socket screw
1 472 Circlip 4 914.8*** Socket screw
* Only for size5–26 and55-85
*** Only for type LVI/LVT: replaces 914.1
Tab.23: Maintenance kit magnetic coupling
Operating instructions
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16 Spare parts
048
048
879.2
661
042
471.2
914.1
165.1
164
501
305
222
16.3 Repair kits
16.3 Repair kits
16.3.1 Repair kit screw set LFI/LVI/LFT/LVT/LFM
Notice The repair kit is only supplied in combination with a maintenance kit.
Qty. Item No. Part Qty. Item No. Part
1 042 Balancing cylinder 1 661 Screw set
2 048 Balancing bush 1 879.2 Straight pin
1 471.2 Circlip
Tab.24: Repair kit screw set LFI/LVI/LFT/LVT/LFM
16.3.2 Repair kit overflow valve LFI/LVI/LFT/LVT/LFM
Notice The repair kit contains only the numbered parts and is only supplied complete.
Qty. Item No. Part Qty. Item No. Part
1 164 Adjusting screw 1 305 Valve body
1 165.1 Screw plug 1 501 Pressure spring
1 222 Flat gasket 4 914.1 Socket screw
Tab.25: Repair kit overflow valve LFI/LVI/LFT/LVT/LFM
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16.3.3 Repair kit magnetic coupling
917.1**
914.7
585
914.6
917**
063**
515
052
038
518
739
040
884**
Notice The repair kit contains only the numbered parts and is only supplied complete.
16 Spare parts
16.3 Repair kits
Fig.14: Repair kit magnetic coupling LFI/LVI/LFT/LVT/LFM
Qty. Item No. Part Qty. Item No. Part
1 038 Containment can 1 739 O-ring
1 040 Distance sleeve 1 884** Threaded pin
1 052 Outer rotor support 4 914.6 Socket screw
1 063** Supporting ring 4 (8*) 914.7 Socket screw
1 515 Outer rotor 1 917** Countersunk screw
1 518 Inner rotor 2 917.1** Countersunk screw
1 585 Tensioning element
* From Size 32
** Depending on motor size
Tab.26: Repair kit magnetic coupling LFI/LVI/LFT/LVT/LFM
Operating instructions
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16 Spare parts
914.6
914.5
180
914.7
894
585
914.3
914.4
917**
917.1**
063**
515
052
038
518
739
040
884**
16.4 Completions
16.4 Completions
16.4.1 Completion type LFI/LVI/LFT/LVT/LFM
Fig.15: Completion
Qty. Item No. Part Qty. Item No. Part
1 038 Containment can 1 884** Threaded pin
1 040 Distance sleeve 3 894 Hexagon nut
1 052 Outer rotor support 4 914.3 Socket screw
1 063** Supporting ring 3 914.4 Socket screw
1 180 Pump bracket 4 914.5 Socket screw
1 515 Outer rotor 4 914.6 Socket screw
1 518 Inner rotor 4 (8*) 914.7 Socket screw
1 526 Pump bracket foot 1 917** Countersunk screw
1 585 Tensioning element 2 917.1** Countersunk screw
1 739 O-ring
* From Size 32
** Depending on motor size
Tab.27: Completion type LFI/LVI/LFT/LVT/LFM
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17 Appendix
17.1 Tightening torque for screws with metric screw threads and head contact surfaces
17 Appendix
17.1 Tightening torque for screws with metric screw threads and head contact surfaces
Tightening torque [Nm]
+ Wedge lock washers
Thread 5.6 5.8 10.9 8.8+
Alu*
M 3 0.6 1.5 – 1.2 1.5 1.1 – –
M 4 1.4 2.9 4.1 2.3 3.0 2.0 – –
M 5 2.7 6.0 8.0 4.8 6.0 3.9 3.5 4.7
M 6 4.7 9.5 14.0 7.6 10.3 6.9 6.0 8.0
M 8 11.3 23.1 34.0 18.4 25.0 17.0 16.0 22.0
M 10 23.0 46.0 68.0 36.8 47.0 33.0 32.0 43.0
M 12 39.0 80.0 117 64.0 84.0 56.0 56.0 75.0
M 14 62.0 127 186 101 133 89.0 – –
M 16 96.0 194 285 155 204 136 135 180
M 18 133 280 390 224 284 191 – –
M 20 187 392 558 313 399 267 280 370
M 24 322 675 960 540 687 460 455 605
Tab.28: Tightening torques metric screw thread
8.8 Rustproof
A4-70
Stainless steel screws A2
and A4
Property
class 70
Property
class 80
* Reduced tightening torque when screwing into aluminium
17.2 Tightening torques for screw plugs with thread measured in inches and elastomer seal
Tightening torque [Nm]
Thread Galvanized + stainless steel
G 1/8" 13.0
G 1/4" 30.0
G 3/8" 60.0
G 1/2" 80.0
G 3/4" 120
G 1" 200
G 1 1/4" 400
G 1 1/2" 450
Tab.29: Tightening torques, thread measured in inches
17.3 Tightening torques for screws of tensioning elements
Tightening torque [Nm]
Thread 12.9
M 3 1.8
M 4 4.0
M 6 16.0
M 8 37.0
M 10 73.0
M 12 126
Tab.30: Tightening torques tensioning elements
Operating instructions
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17 Appendix
17.4 Contents of the Declaration of Conformity
17.4 Contents of the Declaration of Conformity
The products described in these instructions are machinery in the sense of the Directive 2006/42/EC.
The original of the EC Declaration of Conformity is enclosed with the machinery at delivery.
The machinery fulfils all the relevant provisions of the following directives:
Number Name Remark
2006/42/EC Machinery Directive –
2014/68/EU Pressure Equipment Directive –
2014/30/EU Directive on Electromagnetic
2014/35/EU Low Voltage Directive Only for machinery with electrical
2014/34/EU Directive on Use in Potentially
Tab.31: Directives observed
Compatibility
Explosive Areas (ATEX)
Only for machinery with electrical
components
components
Only for machinery in ATEX version
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Directory of figures
Directory of figures
Fig. 1 Type code...................................................................................................................................................................... 10
Fig. 2 Rating plate ................................................................................................................................................................... 11
Fig. 3 Pump structure .............................................................................................................................................................. 15
Fig. 4 Pump unit structure ....................................................................................................................................................... 15
Fig. 5 Overflow valve ............................................................................................................................................................... 17
Fig. 6 Fastening of hoisting equipment - principle diagrams ................................................................................................... 18
Fig. 7 Flow direction ................................................................................................................................................................ 22
Fig. 8 Connection to pipe system ............................................................................................................................................ 24
Fig. 9 Vent holes ..................................................................................................................................................................... 28
Fig. 10 Pressure gauge shut-off valves closed/open - principle diagram ................................................................................. 30
Fig. 11 Overflow valve ............................................................................................................................................................... 31
Fig. 12 Electrical heating system ............................................................................................................................................... 47
Fig. 13 Fluid heating system ..................................................................................................................................................... 49
Fig. 14 Repair kit magnetic coupling LFI/LVI/LFT/LVT/LFM ..................................................................................................... 53
Fig. 15 Completion .................................................................................................................................................................... 54
Directory of tables
Tab. 1 Target groups ................................................................................................................................................................ 4
Tab. 2 Type code...................................................................................................................................................................... 10
Tab. 3 Operating limits.............................................................................................................................................................. 11
Tab. 4 Sound pressure level..................................................................................................................................................... 12
Tab. 5 Required NPSH values ................................................................................................................................................. 12
Tab. 6 Weights type LFI/LFT/LFM ............................................................................................................................................ 13
Tab. 7 Weights type LVI/LVT.................................................................................................................................................... 14
Tab. 8 Materials ........................................................................................................................................................................ 14
Tab. 9 Housing variants............................................................................................................................................................ 16
Tab. 10 Conditions for additional preservation ........................................................................................................................... 19
Tab. 11 Measures during operation interruptions....................................................................................................................... 33
Tab. 12 Measures depending on the behaviour of the pumped liquid........................................................................................ 33
Tab. 13 Required maintenance .................................................................................................................................................. 34
Tab. 14 Magnetic coupling: Parts to be maintained ................................................................................................................... 35
Tab. 15 Fault table...................................................................................................................................................................... 45
Tab. 16 Scope of delivery of electrical heating system ............................................................................................................. 47
Tab. 17 Operating data electrical heating system ...................................................................................................................... 47
Tab. 18 Heating-up period for electric heating system ............................................................................................................... 47
Tab. 19 Scope of delivery of the fluid heating system ................................................................................................................ 49
Tab. 20 Heating liquid operating data......................................................................................................................................... 49
Tab. 21 Heating-up period for fluid heating system.................................................................................................................... 49
Tab. 22 Overview of spare parts ................................................................................................................................................ 50
Tab. 23 Maintenance kit magnetic coupling .............................................................................................................................. 51
Tab. 24 Repair kit screw set LFI/LVI/LFT/LVT/LFM ................................................................................................................... 52
Tab. 25 Repair kit overflow valve LFI/LVI/LFT/LVT/LFM............................................................................................................ 52
Tab. 26 Repair kit magnetic coupling LFI/LVI/LFT/LVT/LFM ..................................................................................................... 53
Tab. 27 Completion type LFI/LVI/LFT/LVT/LFM......................................................................................................................... 54
Operating instructions
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Directory of tables
Tab. 28 Tightening torques metric screw thread ........................................................................................................................ 55
Tab. 29 Tightening torques, thread measured in inches ............................................................................................................ 55
Tab. 30 Tightening torques tensioning elements........................................................................................................................ 55
Tab. 31 Directives observed....................................................................................................................................................... 56
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