OSNA CVP 423, CVP 426, CVP 428 Operating Manual
Ver.17-01
Original Operating Manual
CVP High-Pressure Centrifugal Pump
OSNA-Pumpen GmbH
Brückenstrasse 3
49090 Osnabrück, Germany
Phone: +49 541 1211 - 0
Fax: +49 541 1211 - 220
Internet: http://www.osna.de
E-mail: info@osna.de
CVP High-Pressure Centrifugal Pump 1
Contents
1 GENERAL ...................................................................................................................................4
1.1 About this operating manual ..................................................................................................4
1.2 Target groups .......................................................................................................................4
1.3 Other valid documents ..........................................................................................................4
1.4 Warning notices and symbols ................................................................................................5
1.5 Copyright/changes ................................................................................................................5
2 SAFETY ......................................................................................................................................6
2.1 Correct and proper use .........................................................................................................6
2.2 General safety instructions ....................................................................................................7
2.2.1 Product safety ................................................................................................................7
2.2.2 Duties of the system owner ............................................................................................7
2.2.3 Duties of personnel ........................................................................................................8
2.3 Dangers of non-observance of the safety instructions ............................................................9
2.4 Unauthorized conversion and production of spare parts.........................................................9
2.5 Unauthorized modes of operation ..........................................................................................9
2.6 Special hazards ....................................................................................................................9
2.6.1 Explosion area ...............................................................................................................9
2.6.2 Hazardous pumping media .............................................................................................9
2.6.3 Noise emissions .............................................................................................................9
3 LAYOUT AND FUNCTION ........................................................................................................ 10
3.1 Labeling .............................................................................................................................. 10
3.2 Scope of delivery for a type-CVP high-pressure centrifugal pump ........................................ 10
3.3 General information............................................................................................................. 11
3.4 Technical data .................................................................................................................... 11
4 TRANSPORT AND INTERMEDIATE STORAGE ....................................................................... 13
4.1 Transport ............................................................................................................................ 13
4.1.1 Unpacking and checking the delivery condition ............................................................. 13
4.1.2 Lifting ........................................................................................................................... 13
4.2 Intermediate storage ........................................................................................................... 14
4.3 Storage ............................................................................................................................... 14
4.4 Disposal .............................................................................................................................. 15
5 ASSEMBLY AND INSTALLATION ............................................................................................ 16
5.1.1 Preparing the installation location ................................................................................. 16
5.1.2 Preparing the base surface and foundations ................................................................. 16
5.2 Installation .......................................................................................................................... 16
5.2.1 Installing the pump ....................................................................................................... 16
5.2.2 Assembling the motor................................................................................................... 17
2 CVP High-Pressure Centrifugal Pump
5.2.3 Electrical connection .................................................................................................... 18
5.2.4 Adjusting the pump rotor .............................................................................................. 19
5.3 Pipelines ............................................................................................................................. 20
6 COMMISSIONING/ DECOMMISSIONING ................................................................................. 22
6.1 Commissioning ................................................................................................................... 22
6.1.1 Determining the pump configuration ............................................................................. 22
6.1.2 Filling the pump ............................................................................................................ 22
6.1.3 Checking direction of rotation ....................................................................................... 22
6.1.4 Starting the pump ......................................................................................................... 23
6.2 Decommissioning ................................................................................................................ 24
6.2.1 Draining the pump and protecting against frost ............................................................. 25
6.3 Recommissioning ................................................................................................................ 25
6.4 Mechanical seal .................................................................................................................. 25
7 MAINTENANCE AND REPAIR .................................................................................................. 27
7.1 General information............................................................................................................. 27
7.2 Sending the pump to the manufacturer ................................................................................ 28
8 FAULTS AND TROUBLESHOOTING........................................................................................ 29
9 APPENDIX ................................................................................................................................ 32
9.1 Service, spare parts, accessories ........................................................................................ 32
9.2 Individual parts of the CVP centrifugal pump ....................................................................... 33
9.3 Declaration of Conformity as per EC Directive 2006/42/EC, Annex IIA ................................. 35
9.4 Clearance Certificate ........................................................................................................... 36
CVP High-Pressure Centrifugal Pump 3
List of Tables
Table 1: Target groups and their tasks ................................................................................................4
Table 2: Other valid documents and their purposes ............................................................................4
Table 3: Warning notices and consequences of non-observance ........................................................5
Table 4: Symbols and their meanings ..................................................................................................5
Table 5: Values table CVP 423 ......................................................................................................... 12
Table 6: Values table CVP 426 ......................................................................................................... 12
Table 7: Values table CVP 428 ......................................................................................................... 12
Table 8: Measures in the event of operational interruption ................................................................ 24
Table 9: Measures depending on the behavior .................................................................................. 24
Table 10: Measures following longer shut down times ....................................................................... 25
Table 11: Measures for return ........................................................................................................... 28
Table 12: Fault/number allocation ..................................................................................................... 29
Table 13: Troubleshooting table ........................................................................................................ 31
Table 14: Parts list of the CVP centrifugal pump ................................................................................ 34
List of Images
Figure 1: CVP model code ................................................................................................................ 10
Figure 2: Scope of delivery for type CVP ........................................................................................... 10
Figure 3: Dimensions on the CVP centrifugal pump ........................................................................... 11
Figure 4: Lifting a CVP centrifugal pump ........................................................................................... 13
Figure 5: Foundation plan for CVP 423 to 428 ................................................................................... 17
Figure 6: Overhead view of coupling ................................................................................................. 18
Figure 7: Adjusting the pump rotor .................................................................................................... 19
Figure 8: Functional and operating elements ..................................................................................... 20
Figure 9: Explosion diagram of the CVP centrifugal pump ................................................................. 33
1 General
4 CVP High-Pressure Centrifugal Pump
1 General
1.1 About this operating manual
This operating manual contains important instructions that must be observed during installation, operation and maintenance. For this
reason, ensure that it is read by specialist personnel and the responsible operator/owner
prior to assembly and commissioning. The
manual must be available at all times at the location where the system is used.
Please observe the safety instructions described in this operating manual, along with the
relevant national accident prevention regulations and any internal work, operational and
safety specifications of the operator. We assume no liability for damages and operational
interruptions resulting from non-observance of
this operating manual.
WARNING
Pay particular attention to section 2 "Safety instructions" during commissioning and all
maintenance work.
Section 2 also provides an explanation of the
symbols used in this manual. Knowledge of
this operating manual is essential to preventing
errors and ensuring safe and uninterrupted
operation.
The operating specification does not take local
safety regulations into account. The owner
bears full responsibility for compliance with
these, including on the part of the assembly
personnel used.
This operating manual:
· is part of the pump
· is valid for all type series mentioned
· describes safe and proper use in all
phases of operation
1.2 Target groups
Target group
Task
System owner
► Ensure that this manual is available at the location where the system is
used, including for later
reference.
► Ensure that personnel
read and observe this operating manual and the
other valid documents, in
particular the safety and
warning information.
► Observe additional
system-related regulations and specifications.
Specialist personnel,
assembly staff
► Read, observe and follow this operating manual
and the other valid documents, in particular the
safety and warning information.
Table 1: Target groups and their tasks
1.3 Other valid documents
Document
Purpose
Installation diagram Installation dimensions,
connection dimensions,
etc.
Spare parts list
Ordering spare parts
Clearance certificate Returning the pump
Declaration of
conformity
Conformity with stand-
ards, content of the dec-
laration of conformity
Table 2: Other valid documents and
their purposes
1 General
CVP High-Pressure Centrifugal Pump 5
1.4 Warning notices and symbols
Warning notice
Hazard
level
Consequences of nonobservance
DANGER
Immediate
hazard
Death, severe
physical injury
WARNING
Potential
hazard
Death, severe
physical injury
CAUTION
Potentially
dangerous
situation
Minor physical
injury
NOTICE
Potentially
dangerous
situation
Material damage
Table 3: Warning notices and consequences of
non-observance
Symbol
Meaning
Safety sign
► Follow all instructions
identified with safety signs
in order to avoid death or
injuries.
► Instruction
1. , 2. , … Instruction with multiple
steps
Condition
→ Reference
Information, note
Table 4: Symbols and their meanings
1.5 Copyright/changes
The intellectual property and all copyrights related to this technical documentation remain
exclusively with OSNA-Pumpen GmbH. All
rights reserved, in particular the right to reproduction and distribution of this documentation,
including translations thereof.
No part of this documentation may be reproduced in any form (print, photocopy, microfilm
or any others process), stored, processed, reproduced or distributed using electronic systems without written permission.
Editorial changes reserved exclusively by
OSNA-Pumpen GmbH.
Any violation is punishable and subject to
compensation.
OSNA GmbH reserves the right to change the
contents of this documentation without notice.
2 Safety
6 CVP High-Pressure Centrifugal Pump
2 Safety
The manufacturer shall not bear any liability
for damages caused as a result of nonobservance of this documentation.
2.1 Correct and proper use
· Only use this pump for the purposes of
conveying the agreed pumping media.
· Comply with operating limits.
· The pumping medium may not contain
any abrasive or long-fibered components that may damage the pump materials. Consult the manufacturer if using other media.
· Ensure that the pump is only commissioned with pumping medium and is
not operated without it.
· Open the suction-side fitting, and do
not use it to control the flow rate.
· To avoid damaging the motor, observe
the permitted number of times per
hour that the motor can be switched
on (→ Manufacturer information).
· Any other use must be agreed with the
manufacturer.
· The temperature of the pumping medium must not exceed 80 °C.
Avoiding obvious misuse (examples)
· Observe the operating limits of the
pump for temperature, pressure, flow
rate and speed.
The main areas of use are:
· Pressure boosting systems, heating
systems, hot and cooling water circulation, water supply systems, power stations, filtering systems, fire extinguisher and sprinkler systems, and processing machinery
· Fresh water, drinking water, boiler
feed water, process water, sea and
brackish water, hot water, condensate,
lyes, drilling and cutting oils, and many
media without aggressive components
that do not chemically corrode the materials used in the pump
Do not operate the pump without pumping medium. Dry running can lead to damage to the
pump.
Ensure that the foot valve is in the pumping
medium at all times during suction.
WARNING
Any use that goes beyond the purposes
described above shall be considered improper use. OSNA shall bear no liability for
any resulting damages. The owner bears
full risk for improper use.
2 Safety
CVP High-Pressure Centrifugal Pump 7
2.2 General safety instructions
Please observe the following specifications
before performing any activities.
2.2.1 Product safety
This pump is constructed according to the latest state of the art and accepted safety rules.
Nevertheless, risks to life and limb for the user
or third parties are still possible when using the
pump, as are impairments to the pump and
other material assets.
· Only use the pump in a technically
perfect state and for the intended purpose. Ensure compliance with this operating manual and be aware of the
hazards and safety issues during operation.
· Keep this operating manual and all
other valid documents in a complete
and legible state, and store in a location that is accessible at all times to
personnel.
· Do not permit any activity that endangers personnel or uninvolved third parties.
· In the event of a safety-relevant fault,
stop the pump immediately and have
the fault rectified by responsible personnel.
· In addition to this documentation, ensure compliance with the statutory or
other regulations for safety and accident prevention, as well as the relevant standards and specifications of
the respective country.
· Do not remove any technical stickers.
2.2.2 Duties of the system owner
Safety-conscious work
Observe the safety specifications detailed in
this operating manual, along with the occupational safety regulations and all additional internal safety regulations.
· Only use the pump in a technically
perfect state and for the intended purpose. Ensure compliance with this operating manual and be aware of the
hazards and safety issues during operation.
· Ensure compliance and monitoring:
- correct and proper use
- statutory or other safety and acci-
dent prevention regulations
- safety specifications for handling
hazardous substances
· Provide personal protective equipment.
· Do not remove contact protection during operation.
· Prevent any dangers from electrical
energy (for details, please refer to the
specifications of the VDE and the local
energy supplier).
· Switch off the motor during all assembly and maintenance works, and secure against reactivation.
· Only work on the system when the
pump is at a standstill.
2 Safety
8 CVP High-Pressure Centrifugal Pump
Personnel qualification
The owner of the system must ensure that the
personnel tasked with working on the pump
have read and understood this operating manual and all other valid documents before beginning work, in particular information on safety, maintenance and repair.
Work of any kind on the machine may only be
performed when it has been completely decommissioned. Reinstall and reactivate all
safety mechanisms after work.
Before restarting the machine, ensure that all
necessary commissioning steps have been
completed (→ 6.1 Commissioning, pg 22).
· Determine responsibilities, tasks and
monitoring for personnel.
· Only allow work of any kind to be performed by specialist technical personnel:
- assembly, maintenance and repair
work
- work on the electrical systems
· Only allow personnel undergoing training to perform work on the pump under
the supervision of specialist technical
personnel.
Safety mechanisms
· Provide the following safety mechanisms and ensure that they function
correctly:
- for moving components: contact
protection for the pump, installed
by the customer
- for potential electrostatic charges:
provide appropriate earthing
Guarantee
· Please consult the manufacturer before carrying out any conversions, repairs or changes during the guarantee
period.
· Only use original parts or parts approved by the manufacturer.
2.2.3 Duties of personnel
· Observe the information on the pump
and ensure it is legible (e.g. direction
of rotation arrow, fluid connection indicators).
· Do not remove the contact protection
for moving parts during operation.
· Use personal protective equipment if
necessary.
· Only work on the system when the
pump is at a standstill.
· Switch off the motor during all assembly and maintenance works, and secure against reactivation.
· Reinstall the safety mechanisms after
working on the pump according to
specifications.
2 Safety
CVP High-Pressure Centrifugal Pump 9
2.3 Dangers of non-observance of
the safety instructions
· Non-observance of the safety instructions can lead to hazards to personnel,
the machine and the environment.
· Non-observance of the safety instructions can also lead to the loss of any
damage claims.
· In particular, non-observance can lead
to the following dangers:
- failure of important system func-
tions
- electrical and mechanical hazards
to personnel
2.4 Unauthorized conversion and
production of spare parts
Conversions or changes to the machine are
only permitted following consultation with the
manufacturer. Original spare parts and accessories authorized by the manufacturer help ensure safety. The manufacturer bears no liability
for the consequences of the use of other parts.
2.5 Unauthorized modes of operation
The operational safety of the machine is only
guaranteed when it is used for the intended
purpose according to the operating manual (→
2.1 Correct and proper use, pg 6).
Never exceed the limit values indicated in the
technical data (→ 3.4 Technical data, pg 11).
2.6 Special hazards
2.6.1 Explosion area
· Do not use the pump in areas where
there is a risk of explosion.
2.6.2 Hazardous pumping media
· Observe the safety regulations for
handling hazardous substances (e.g.
toxic, hazardous to health).
· Use personal protective equipment
when performing work on the pump.
2.6.3 Noise emissions
The maximum continuous sound pressure level of a correctly installed and commissioned
CVP high-pressure centrifugal pump is 70
dB(A).
3 Layout and function
10 CVP High-Pressure Centrifugal Pump
3 Layout and function
3.1 Labeling
This operating manual applies to pumps of the
CVP 423, CVP 426 and CVP 428 series.
Model code:
Figure 1: CVP model code
3.2 Scope of delivery for a typeCVP high-pressure centrifugal pump
The customer can order the pump:
· in a preassembled state, i.e. delivery
without motor. The motor is installed
by the customer.
· in a fully assembled state, i.e the
pump is fitted with motor ex-works.
Figure 2: Scope of delivery for type CVP
1 Pump
2 Drive motor
3 Coupling guard
4 Delivery-side counter flange
5 Suction-side counter flange (oval)
The scope of delivery corresponds to the
scope indicated in the order. Please check that
the delivery is complete upon receipt. Notify
the delivery company of any transport damage
immediately. Please also refer to our conditions of sale and delivery.
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