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: [phone] - 0
Fax: [phone] - 220
Internet: http://www.osna.de
E-mail: [email protected]

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.

3 Layout and function

CVP High-Pressure Centrifugal Pump 11

3.3 General information

The CVP is a non-self-priming, multi-stage
high-pressure centrifugal pump in a vertical
configuration (staged centrifugal pump). It fea­tures a variable connection point. The pumps
are fitted with mechanical seals. Fluid­lubricated plain bearings are used. Materials:
The shafts and impellers are made from stain­less steel, the diffusers and wear plates are
made from plastic, the suction and delivery
casings are made from gray cast iron, and the
stage casing is made from steel (stainless
steel available). Other materials are also used

depending on customer requirements or the
needs of the pumping medium. Only drive CVP
pumps with electric motors that have a fixed
bearing that cannot be shifted from the B side
to the A side. The complete unit is fully as­sembled and includes the pump, drive motor,
coupling and coupling guard.

3.4 Technical data

Please check the pump type on the type

plate to determine the correct gap.

Figure 3: Dimensions on the CVP centrifugal pump

3 Layout and function

12 CVP High-Pressure Centrifugal Pump

CVP 423

Flow rate at n = 2900 min-1

Motor l/min 16.7 33.3 50 66.7 83.3 100 116.7 133.3 150 166.7 183.3

No. of Pump Output m³/h 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

stages H size (kW) L B Total delivery head m

2 166 71 0.37 493 292 423/ 2 19 18 17 16 14 11 8
4 242 80 0.75 600 373 423/ 4 39 38 35 32 28 22 16
6 318 80 1.1 676 449 423/ 6 59 56 53 48 41 33 24

8 394 90 1.5 768 525 423/ 8 79 75 71 64 55 44 32
10 470 90 2.2 869 601 423/10 98 94 88 79 69 55 39
12 546 90 2.2 945 677 423/12 118 113 106 95 83 66 47
14 622 100 3.0 1068 763 423/14 137 131 123 111 96 77 55
16 698 100 3.0 1144 839 423/16 157 150 141 127 110 88 63
18 774 112 4.0 1234 915 423/18 177 169 159 143 124 99 71

Table 5: Values table CVP 423

CVP 426

Flow rate at n = 2900 min-1

Motor l/min 16.7 33.3 50 66.7 83.3 100 116.7 133.3 150 166.7 183.3

No. of Pump Output m³/h 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

stages H size (kW) L B Total delivery head m

2 166 71 0.55 493 292 426/ 2 22 22 21 20 19 18 17 15 12

9 6

4 242 80 1.1 600 373 426/ 4 44 43 42 41 39 37 33 29 25 19 12

6 318 90 1.5 692 449 426/ 6 65 64 63 61 59 55 50 44 37 28 17

8 394 90 2.2 793 525 426/ 8 87 86 84 82 78 73 67 59 49 37 23
10 470 100 3.0 916 611 426/10 108 107 105 102 98 91 83 73 61 46 29
12 546 112 4.0 1006 687 426/12 130 128 126 122 117 110 100 88 73 56 35
14 622 112 4.0 1082 763 426/14 151 149 147 143 137 128 116 102 86 65 40
16 698 132 5.5 1221 859 426/16 173 171 168 163 156 146 133 117 98 74 46
18 774 132 5.5 1297 935 426/18 195 192 189 183 176 164 150 132 110 83 52

Table 6: Values table CVP 426

CVP 428

Flow rate at n = 2900 min-1

Motor l/min 16.7 50.0 83.3 116.7 150 166.7 183.3 200 216.7 233.3 250

No. of Pump Output m³/h 1.0 3.0 5.0 7.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0

stages H size (kW) L B Total delivery head m

2 166 80 1.1 524 297 428/ 2 25 25 24 22 20 19 18 17 16 14 13

4 242 90 2.2 641 373 428/ 4 49 48 46 44 40 38 36 34 31 28 25

5 280 90 2.2 679 411 428/ 5 62 60 58 55 50 48 45 42 39 35 31

6 318 100 3.0 764 459 428/ 6 74 72 69 65 60 58 54 51 47 42 38

8 394 112 4.0 854 535 428/ 8 99 96 92 87 80 77 72 68 62 56 50

10 470 132 5.5 993 631 428/10 124 120 116 109 100 96 90 85 78 70 63

Table 7: Values table CVP 428

Note: 1) CVP 423 and 426/2-10 with V 18 small three-phase motor

2) CVP 423 and 426/12-18, and 428/2-10 V 1 three-phase motor and delivery casing with
threaded counter flange (round) R 1 1/4" PN 25; DIN 2567

3) Motor output applies to 50-Hz/2-pole three-phase motors

4 Transport and intermediate storage

CVP High-Pressure Centrifugal Pump 13

4 Transport and intermediate
storage

4.1 Transport

Weight information (→ Other valid docu-

ments)

4.1.1 Unpacking and checking the de­livery condition

1. Check that the delivery is complete
upon receipt.

2. Unpack the pump/unit upon delivery
and check for transport damage.

3. Notify the delivery company of any
transport damage immediately.

4. Dispose of the packaging material in
line with the applicable local regula­tions.

4.1.2 Lifting

DANGER

Risk of death or crushed limbs from falling
transported goods!

► Choose lifting equipment that is suitable for
the total weight to be transported.

► Do not stand under suspended loads.

Figure 4: Lifting a CVP centrifugal pump

4 Transport and intermediate storage

14 CVP High-Pressure Centrifugal Pump

4.2 Intermediate storage

Ensure during intermediate storage that the
pump is not exposed to any weather conditions
for a long period of time. If the pump is de­commissioned for a longer period of time (ap­proximately 2 to 3 months), ensure that it is ful­ly drained. (→ 6.2 Decommissioning, pg 24)

4.3 Storage

NOTICE

Material damage due to incorrect storage!

► Ensure that the pump is correctly stored.

1. Close all openings with blank flanges,
blind plugs or plastic covers.

2. Ensure that the storage area meets
the following conditions:

–

dry

–

free of frost

–

free of vibrations

3. Rotate the shaft once per month by
several rotations.

NOTICE

Damage to bearings due to high water
pressure or splashing water!

► Do not use water jets or steam jet cleaners

to clean the bearing areas and motor.

NOTICE

Damage to seals due to incorrect cleaning
agent!

► Ensure that the cleaning agent does not

corrode the seals.

1. Choose the cleaning agent according
to the area of use.

2. Dispose of preservatives in line with
the applicable local regulations.

3. When storing for longer than 6
months:

–

Check all elastomers (round seals,
shaft seal rings, gaskets and gland
packing) for elasticity, and replace
if necessary.

4 Transport and intermediate storage

CVP High-Pressure Centrifugal Pump 15

4.4 Disposal

Plastic parts may be contaminated by toxic

or radioactive pumping media. If this is the
case, cleaning is not sufficient.

WARNING

Risk of poisoning and environmental dam­age from pumping medium!

► Use personal protective equipment when

performing work on the pump.

► Before disposing of the pump:

–

Collect any remaining pumping
medium in the pump, and dispose
of it in line with the locally valid
regulations.

–

Neutralize any pumping medium
residues in the pump.

► Dispose of the pump in line with the appli-

cable local regulations.

5 Assembly and installation

16 CVP High-Pressure Centrifugal Pump

5 Assembly and installation

NOTICE

Material damage due to contamination!

► Only remove covers, transport caps and

sealing caps immediately before connecting
the pump to the pipelines.

CAUTION

Ensure compliance with all safety specifi­cations during installation and operation.

1. Please consult the manufacturer when
installing at altitudes over 1000 m
above mean sea level.

5.1.1 Preparing the installation loca­tion

► Ensure that the installation location meets

the following conditions:

–

pump is freely accessible from all
sides

–

sufficient space for installing/removing
piping, as well as for maintenance and
repair work, in particular for in­stalling/removing the pump and motor

–

no effects from external vibrations on
the pump (bearing damage)

–

protection against frost

5.1.2 Preparing the base surface and
foundations

► Ensure that the base surface and founda-

tions meet the following conditions:

–

level

–

clean (no oils, dust or other contami­nations)

–

foundations can support the weight of
the pump unit and all operating forces

–

stability of the pump unit ensured

5.2 Installation

5.2.1 Installing the pump

Prior to installation, remove the packaging (if
present) and check the pump for any transport
damage. Ensure that the installation area is
dry and free of frost.

CAUTION

Do not operate the pump in areas where
there is a risk of explosion. Ensure that the
pump is installed and connected in line
with the local regulations.

5 Assembly and installation

CVP High-Pressure Centrifugal Pump 17

We recommend installing the pump on a
noise-insulating base, in order to prevent
transmission noises to parts of the building.

Provide an outlet for leakage fluid during
maintenance work.

The pump's suction casing is shown as the
base, and must be secured free of tension to a
foundation using 4 M12 screws (à Figure 5,
pg 17).

Figure 5: Foundation plan for CVP 423 to 428

CAUTION

Install the pump in such a way that pre­vents flooding of building sections as the
result of a leak or when performing mainte­nance work.

5.2.2 Assembling the motor

Clean the motor shaft of any anti-rust agent
and remove the keys if present.

Remove the socket head cap screws (29 and

30) of the coupling shells (28), place the motor
on the delivery casing (20 or 26), and secure
with screws (see Table 14, pg 34). Manually
tighten the socket head cap screws on the
coupling shells slightly, ensuring that the gap
between the coupling shells is even (à Figure
6, pg 18). Please also refer to 6.1.3 Checking
direction of rotation, pg 22 for information on
checking the direction of rotation.

5 Assembly and installation

18 CVP High-Pressure Centrifugal Pump

Figure 6: Overhead view of coupling

CAUTION

Incorrect direction of rotation on the pump
can lead to damage to the mechanical seal
and a reduction in performance. The pump
shaft must rotate clockwise, as seen from
the motor.

DANGER

Never operate the pump without the cou­pling guard.

DANGER

Risk of death due to rotating parts!

► Use personal protective equipment when

performing work on the pump.

► Prevent the keys from being slung away
when checking the direction of rotation.

► Ensure sufficient clearance to rotating

parts.

5.2.3 Electrical connection

CAUTION

Electrical connection must be carried out
by a specialist electrician, in line with the
specifications of the local energy supplier
or the VDE.

Install a motor protection switch to protect the
motor.

5 Assembly and installation

CVP High-Pressure Centrifugal Pump 19

5.2.4 Adjusting the pump rotor

The rotor is not set on pumps that are fitted

with an electric motor ex-works.

Only drive CVP pumps with electric motors
that have a fixed bearing that cannot be shifted
from the B side to the A side.

Setting the rotor requires a fitting lever, a
marking tool, a power drill, a screwdriver and a
hexagonal socket wrench.

1. Press the pump rotor down together
with the coupling shells until the impel-

lers are in axial contact with the wear
plate. Mark the pump shaft.

2. Raise the pump rotor with the coupling
shells by the "y" dimension (à Figure
7, pg 19) and mark the pump shaft.

3. Evenly tighten the socket head cap
screws (29 and 30) (à Figure 6, pg 18
and Figure 7, pg 19).

4. Check the pump rotor setting.

5. Drill a hole in the motor shaft and se­cure the coupling shells against axial
shift with a grub screw (31).

Figure 7: Adjusting the pump rotor

5 Assembly and installation

20 CVP High-Pressure Centrifugal Pump

5.3 Pipelines

Determine the nominal widths of the pipelines,
taking the local conditions into account. To
keep flow losses to a minimum, avoid sudden
constrictions and sharp bends. Route pipelines
free of tension and pressure tight. Install them
in a way that prevents forces and torques be­ing transferred to the pump. Never use the
pump as an anchor point for the pipeline.

Fit the suction pipe rising to the pump and the
inlet pipe declining to the pump, in order to
prevent the formation of air bubbles. Support
the pipes immediately before the pump, and
connect without tension. Ensure that the
weight of the pipes does not strain the pump. If
using short pipes, the nominal widths must be
at least equal to those of the pump connec­tions. If using long pipelines, determine the
cost-effective nominal width on a case-by-case
basis.

Taper pieces to larger nominal widths should
have an extending angle of approx. 8° to pre­vent increased pressure losses. Install check
valves and shut-off devices depending on the
type of system and pump (à Figure 8, pg 20).

Take appropriate measures to compensate
any expansions of the pipelines caused by
temperature influences, in order to avoid
straining the pump with forces and torques.

CAUTION

Before commissioning new systems, the
tanks, pipelines and connections must be
thoroughly cleaned, flushed and blown
through. Welding beads, scales and other
contaminations often only fall off after a
longer period of time. Ensure that they are
kept away from the pump by fitting a
strainer in the suction pipe.

Figure 8: Functional and operating elements

Key:

1 Centrifugal pump
2* Foot valve with suction/inlet strainer
3* Suction pipe
4* Inlet pipe
5* Shut-off valve
6* Pressure gauge
7* Delivery pipe
8* Check valve
9* Control fitting

10* Pressure gauge

* not included in delivery

5 Assembly and installation

CVP High-Pressure Centrifugal Pump 21

Suction or inlet pipe

(à Figure 8, pg 20, 3 and 4)

Keep the suction pipe as short as possible,
and route it in such a way that it is constantly
rising to the pump. Route the inlet pipe con­stantly declining to the pump.

Provide a draining mechanism at the lowest
point of the inlet pipe during inlet operation.

The CVP 428 requires a suction or inlet

pipe of at least R 2“.

Foot valve

(à Figure 8, pg 20, 2)

The foot valve keeps the suction pipe filled
with pumping medium.

Inlet sieve or strainer

(à Figure 8, pg 20, 11)

An inlet sieve or strainer protects the pump
against large-grain contaminations.

Monitoring fitting

(à Figure 8, pg 20, 6)

Monitoring fittings are required to monitor the
suction and inlet pressure. Monitoring valves
help monitor the operating data.

Shut-off valve

(à Figure 8, pg 20, 5)

A shut-off valve is used to block the pipe dur­ing assembly. The shut-off valve must be fully
opened when the pump is in operation.

Delivery pipe

(à Figure 8, pg 20, 7)

Control fitting

(à Figure 8, pg 20, 9)

A control fitting is always required to regulate
the pump power and block the pipeline during
assembly work.

Check valve

(à Figure 8, pg 20, 8)

A check valve is always required to protect the
pump.

6 Commissioning/decommissioning

22 CVP High-Pressure Centrifugal Pump

6 Commissioning/
decommissioning

6.1 Commissioning

6.1.1 Determining the pump configura­tion

► Determine the pump configuration

6.1.2 Filling the pump

CAUTION

Check that there is enough water in the well
or feed tank.

Do not operate the pump without water. Dry
running can lead to damage to the pump.

WARNING

Risk of poisoning or injury due to hazard­ous pumping media!

► Collect any escaping pumping medium

safely and dispose of in an environmentally
friendly way.

NOTICE

Material damage due to dry running!

► Ensure that the pump is properly filled.

6.1.3 Checking direction of rotation

CAUTION

Incorrect direction of rotation on the pump
can lead to damage to the mechanical seal
and a reduction in performance. The pump
shaft must rotate clockwise, as seen from
the motor.

The cast direction of rotation arrow on the
pump indicates the specified direction of rota­tion.

Before checking the direction of rotation, se­cure the pump against activation.

6 Commissioning/decommissioning

CVP High-Pressure Centrifugal Pump 23

DANGER

Risk of death due to rotating parts!

► Use personal protective equipment when

performing work on the pump.

► Prevent the keys from being slung away

when checking the direction of rotation.

► Ensure sufficient clearance to rotating

parts.

After checking the direction of rotation, ensure
that all safety and protective mechanisms are
reinstalled and reactivated.

DANGER

Never operate the pump without the cou­pling guard.

6.1.4 Starting the pump

Pump correctly installed and connect-

ed

Motor correctly installed and connect-

ed

All connections established, sealed

and free of tension

All safety mechanisms installed and

function tested

Pump correctly prepared, filled and

vented

DANGER

Risk of injury due to running pump!

► Do not touch the running pump.
► Do not perform any work on the running

pump.

DANGER

Risk of poisoning or injury due to spurting
pumping medium!

► Use personal protective equipment when

performing work on the pump.

6 Commissioning/decommissioning

24 CVP High-Pressure Centrifugal Pump

NOTICE

Material damage due to dry running!

► Ensure that the pump is properly filled.

NOTICE

Open the suction-side fitting, and do not
use it to control the flow rate. Do not close
the pressure-side fitting!

0.1 MPa = 1 bar ≈ 10 m

6.2 Decommissioning

DANGER

Risk of injury from hazardous pumping
media!

► Collect any escaping pumping medium

safely and dispose of in an environmentally
friendly way.

► Take the following measures in the event of

operating interruptions:

Pump to be Measure

Shut down for
longer period

► Take measures according to
the pumping medium

Drained

► Close suction and delivery-side
fittings.

Disassembled

► Deactivate motor and secure
against unauthorized reactivation.

Put into stor­age

► Observe storage measures
(→ 4.3 Storage, pg 14).

Table 8: Measures in the event

of operational interruption

Flow medium

behavior

Duration of operating inte

r-

ruption (depending on pro­cess)

short

long

Solid compo­nents settle

► Flush
pump.

► Flush

pump.
Solidified/frozen,
non-corrosive

► Heat or
drain pump
and contain­ers.

► Drain

pump and con-

tainers.
Solidified/frozen,

corrosive

► Heat or
drain pump
and contain­ers.

► Drain

pump and con-

tainers.

► Apply pre-

servative to

pump and con-

tainers.
Remains fluid,
non-corrosive

– –

Remains fluid,
corrosive

–

► Drain

pump and con-

tainers.

► Apply pre-

servative to

pump and con-

tainers

Table 9: Measures depending on the behavior

of the pumping medium

Drain the pump completely if shutting down for
a longer period (approx. 2 - 3 months), or if
there is a danger of frost.

6 Commissioning/decommissioning

CVP High-Pressure Centrifugal Pump 25

NOTICE

This work must be carried out by a special­ist service provider.

CAUTION

Disconnect the pump from the electricity
supply if shutting down for a longer period.

6.2.1 Draining the pump and protecting
against frost

The pump must be drained if there is a danger
of frost. A pump that remains empty over a
longer period must be preserved.

6.3 Recommissioning

CAUTION

The pump must move easily for recommis­sioning.

Check that the pump moves easily before re­commissioning.

If the pump was preserved after decommis­sioning, flush it thoroughly before recommis­sioning.

Perform all further work steps in line with 6.1
Commissioning, pg 22.

Take the following measures before recom­missioning following operating interruptions of
> 1 year:

Shut down
time

Measure

> 1 year

► Check visually for leaks

> 2 years

► Replace elastomer seals
(gaskets, round seals, shaft seal
rings and gland packings).
► Replace anti-friction bearings.

Table 10: Measures following longer shut down times

6.4 Mechanical seal

Mechanical seals are self-adjusting mechani­cal shaft seals that require no maintenance.
The mechanical seal must never run dry. En­sure therefore that the pump is filled.

Do not reinstall mechanical seals after remov­ing them for inspection or maintenance. Re­place them with new seals, or relap the contact
surface.

7 Commissioning/decommissioning

26 CVP High-Pressure Centrifugal Pump

NOTICE

Material damage due to dry running!

► Ensure that the pump is properly filled.

7 Maintenance and repair

CVP High-Pressure Centrifugal Pump 27

7 Maintenance and repair

7.1 General information

We can provide trained customer service

technicians for assembly and repair work.
Please present proof of the conveyed
goods upon request.

(DIN safety data sheet or clearance certifi­cate)

DANGER

Risk of injury due to running pump!

► Do not touch the running pump.
► Do not perform any work on the running

pump.

WARNING

Risk of poisoning or injury due to hazard­ous pumping media!

► Use personal protective equipment when

performing work on the pump.

Ensure that the pump runs smoothly and quiet­ly at all times. Maximum permitted room tem­perature 40 °C.

The mechanical seal displays only limited or
invisible leakage losses (in vapor form). It re­quires no maintenance.

The reserve pumps must be activated once
per week in order to ensure operational readi­ness. To do so, switch the reserve pumps on
and immediately off again. Monitor the function
of the additional connections.

The pump shaft is supported in the suction
casing in a zero-maintenance bearing shell
made from PTFE graphite. The pump shaft
and motor shaft are connected rigidly by
means of a muff coupling.

Ensure that the socket head cap screws of the
coupling shells are tightened at regular inter­vals. Perform an initial check after 50 operating
hours, and further checks after every 1,000
operating hours.

DANGER

Risk of death from electric shock!

► Only allow work on the electrical systems to

be carried out by a qualified electrician.

► Ensure that the supply of electricity is

switched off and secured against reactiva­tion when performing all maintenance work.

7 Maintenance and repair

28 CVP High-Pressure Centrifugal Pump

DANGER

Only perform the inspection when the sys­tem is switched off and secured.

7.2 Sending the pump to the manu­facturer

ü Pump depressurized

ü Pump completely drained

ü Electrical connections disconnected

and motor secured against reactivation

ü Manometer removed together with

supply lines and holders

1. Only send pumps or individual compo­nents to the manufacturer together
with a verifiable and completely filled
out clearance certificate. Request a
clearance certificate from the manu­facturer if required.

2. Using the following table, take the ac­tion required for returning the pump
according to the necessary repair.

Repair

Action for return

At customer

► Return defective compo­nent to manufacturer.

At manufacturer

► Flush pump.
► Send complete pump

(not disassembled) to manu-

facturer.
At manufacturer,
with guarantee
claim

► Only if using hazardous

pumping medium: flush pump.

► Send complete pump

(not disassembled) to manu-

facturer.

Table 11: Measures for return

8 Faults and troubleshooting

CVP High-Pressure Centrifugal Pump 29

8 Faults and troubleshooting

Please consult the manufacturer should you
experience any faults that are not described in
the following table, or cannot be traced back to
the described causes.

In the following table, each potential fault is
given a number. Use this number to find the
corresponding cause and remedy in the trou­bleshooting table.

Fault

Number

Pump does not deliver 1
Flow rate too low 2
Flow rate too high 3
Pumping pressure too low 4
Pumping pressure too high 5
Pump runs noisily 6
Temperature of the anti-friction bearings

too high

7

Pump leaks 8
Motor power consumption too high 9

Table 12: Fault/number allocation

Fault number Cause Remedy
1 2 3 4 5 6 7 8 9

X - - - - - - - -

Inlet/suction pipe and/or pressure
pipe closed by fitting

► Open fitting.

- X - X - - - - -

Inlet/suction pipe not completely
opened

► Open fitting.

X X - X - X - - -

Inlet/suction pipe, pump or suction
strainer blocked or encrusted

► Clean inlet/suction pipe, pump or
suction strainer.

- X - X - X - - -

Cross-section of the inlet/suction
pipe too tight

► Enlarge cross-section.
► Clean suction pipe of encrustations.
► Fully open fitting.

X - - - - - - - -

Transport sealing cap not re­moved

► Remove transport sealing cap.
► Disassemble pump and check for

dry running damage.

- X - X - X - - -

Suction head too high: NPSH

pump

is greater than NPSH

system

► Increase inlet pressure.
► Consult manufacturer.

X - - - - X - - -

Inlet/suction pipe and pump not
correctly drained or not complete­ly filled.

► Completely fill and drain pump
and/or pipeline.

X - - - - X - - -

Air pockets in inlet/suction pipe ► Install fitting for venting.

► Correct pipeline routing.

X X - X - X - - -

Air sucked in ► Seal source of fault.

X X - X - X - - -

Gas component too high: pump
cavitated

► Consult manufacturer.

- X - X - X - - - Temperature of pumping medium
too high: pump cavitated

► Increase inlet pressure.
► Reduce temperature.
► Consult manufacturer.

8 Faults and troubleshooting

30 CVP High-Pressure Centrifugal Pump

Fault number Cause Remedy
1 2 3 4 5 6 7 8 9

- X - X - - - - -

Geodetic delivery head and/or
pipeline resistance too high

► Remove deposits in pump and/or
pressure pipe.

► Install larger impeller and consult
manufacturer.

- X - - X X - - -

Pressure-side fitting not opened
far enough

► Open pressure-side fitting.

X X - - X X - - -

Pressure line blocked ► Clean pressure line.

X X - X - X - - -

Incorrect direction of rotation on
pump

► Swap any two phases on motor.

X X - X - - - - -

Speed too low ► Compare required motor speed with

pump type plate. Replace motor if nec­essary.

► Increase speed if possible.

- X - X - X X - -

Pump components worn ► Replace worn pump components.

- - X X - X - - X

Pressure-side fitting opened too
far

► Throttle with pressure-side fitting.
► Machine down impeller. Consult

manufacturer and adjust impeller diam­eter.

- - X - - X - - X

Geodetic delivery head, pipeline
resistance and/or other resistanc­es lower than designed

► Throttle flow rate with pressure-side
fitting. Observe minimum flow rate here.

► Machine down impeller. Consult
manufacturer and adjust impeller diam­eter.

- - X - X - - - -

Viscosity lower than indicated ► Machine down impeller. Consult

manufacturer and adjust impeller diam­eter.

- - X - X X X - X

Speed too high ► Compare required motor speed with

pump type plate. Replace motor if nec­essary.

► Reduce speed if possible.

- - X - X X - - X

Number of stages too high ► Throttle flow rate with pressure-side

fitting. Observe minimum flow rate here.
► Install pump with lower number of

stages.

X X - X - X - - -

Impeller imbalanced or blocked ► Disassemble pump and check for

dry running damage.
► Clean impeller.

- X - X - X - - - Hydraulic pump components dirty,
sticky or encrusted

► Disassemble pump.
► Clean components.

8 Faults and troubleshooting

CVP High-Pressure Centrifugal Pump 31

Fault number Cause Remedy
1 2 3 4 5 6 7 8 9

- - - - - - X - X

Defective anti-friction bearing in
motor

► Replace anti-friction bearing.

- - - - - - X - -

Lubricant: too much, too little or
not suitable

► Reduce, increase or replace lubri­cant.

- - - - - - - X -

Tie bolts not tightened correctly ► Tighten tie bolts.

- - - - - - - X -

Mechanical seal worn ► Replace mechanical seal.

- - - - - - - X -

Defective casing seal ► Replace casing seal.

- - - - - - - X -

Shaft sleeve penetrated ► Replace shaft sleeve and round

seal.

- - - - - X X X X

Pump under tension ► Check pipeline connections and

pump fastening.

► Check coupling alignment.
► Check support foot fastening.

- - - - - X X - -

Coupling incorrectly aligned ► Align coupling.

- X - X - X - - X

Motor runs on 2 phases ► Check fuse and replace if necessary.

► Check wire connections and insula­tion.

Table 13: Troubleshooting table

9 Appendix

32 CVP High-Pressure Centrifugal Pump

9 Appendix

9.1 Service, spare parts, accesso­ries

Please note in particular that spare parts and
accessories not delivered by the manufacturer
are also not checked and approved by the
manufacturer. The installation and/or use of
such products can therefore, under certain cir­cumstances, have a negative effect on the
properties of the centrifugal pump specified in
the design. This can in turn jeopardize safety.
Any liability and guarantee on the part of OS­NA for damages resulting from the use of non­original spare parts and accessories is exclud­ed.

Any faults that cannot be rectified by the owner
may only be rectified by OSNA customer ser­vice or specialist service providers. Please
provide a precise description of the fault, so
that our service technician can prepare and
bring the required spare parts. You can reach
our customer service via the address on the
last page.

Spare parts can be ordered via specialist re­tailers. Please refer to the type plate for the
type designation.

In the event of any guarantee claims, please
provide the machine number on the housing.

The following spare parts diagrams are intend­ed solely to ease the process of finding and
procuring the spare parts.

WARNING

Do not use the spare parts diagrams as as­sembly instructions.

Notes on ordering spare parts:

In order to prevent incorrect deliveries, please
ensure that the information you provide when
ordering is as precise as possible:

· Type designation

· Designation

· Required quantity

· Required shipping method (e.g. post,

freight, express freight, courier deliv­ery)

· Precise delivery address

9 Appendix

CVP High-Pressure Centrifugal Pump 33

9.2 Individual parts of the CVP centrifugal pump

Figure 9: Explosion diagram of the CVP centrifugal pump

9 Appendix

34 CVP High-Pressure Centrifugal Pump

Item Designation Item Designation

1 Suction casing
2 Screwed plug
3 Joint ring
4 O-Ring
5 Flange
6 Gasket
7 Hexagon head bolt
8 Bearing shell
9 Pump shaft with spacer ring
10 Key (round)
11 Wear plate
12 Impeller
13 Diffuser
14 Impeller (top)
15 Grub screw
16 Tie bolt
17 Cap nut

18 Screw lock
19 Stage casing
20 Delivery casing
21 Flange
22 Gasket
23 Hexagon head bolt with nut
24 Mechanical seal
25 Thrower
26 Delivery casing
27 Flange
28 Muff coupling, split
29 Socket head cap screw
30 Socket head cap screw
31 Grub screw
32 Locking sleeve
33 Coupling guard
34 Socket head cap screw

Table 14: Parts list of the CVP centrifugal pump

9 Appendix

CVP High-Pressure Centrifugal Pump 35

9.3 Declaration of Conformity as per EC Directive 2006/42/EC, Annex IIA

We hereby declare under our sole responsibility as manufacturer that the following machine series of
the type, as well as the configurations distributed by us, conform to the relevant specifications of the
EC Machinery Directive 2006/42/EC.

Designation:

CVP 423, 426, 428

Pump number: 172000 - 210000

The machine also corresponds with the following directives published in the Official Journal of the Eu­ropean Union:

· Niederspannungsrichtlinie (2014/35/EU)

· EMV-Richtlinie (2014/30/EU)

· Ökodesignrichtlinie (2009/125/EG)

This declaration shall cease to be valid in the event of any modifications to the machine and/or its pro­tective mechanisms not agreed with us and approved in writing.

Applied harmonized standards and their references in the Official Journal of the European Union:

· DIN EN 809 : 2012

· DIN EN ISO 12100 : 2011

· DIN EN ISO 13732 : 2008

· DIN EN ISO 13849-1 : 2008

· DIN EN ISO 13857-1 : 2008

· DIN EN 60034 : 2007

· DIN EN 60204-1 : 2009

· DIN EN 55024 : 2011

Authorized representative for the composition of technical documentation for OSNA-Pumpen GmbH:

Mr. Rik Arensmann
Brückenstrasse 3
49090 Osnabrück, Germany

Osnabrück, 12.01.2017 _______________________________

Rik Arensmann

Technical Director/QM Officer

9 Appendix

36 CVP High-Pressure Centrifugal Pump

9.4 Clearance Certificate

Please copy and send with the pump.

Clearance Certificate

Legal provisions oblige all businesses to protect their employees, other persons and the environment
from damaging effects when handling hazardous substances. Products and their components may
therefore only be repaired or inspected when the following declaration has been fully and correctly
filled out and singed by an authorized and qualified specialist. Please provide the necessary infor­mation should safety measures on the part of the system owner still be required despite complete
draining and cleaning. This clearance certificate is part of the repair or inspection order.

We hereby assure that the enclosed device

Type: _______________________________________________________________

Serial no.: _______________________________________________________________

is free of substances that are hazardous to health. No special safety measures are required for further
handling. The device was fully drained and thoroughly cleaned inside and outside before dispatch.

Company/institute: _______________________________________________________________

Address: _______________________________________________________________

Town/city, ZIP code: _______________________________________________________________

Phone: _______________________________________________________________

Name: _______________________________________________________________

Position: _______________________________________________________________

Date: _______________________________________________________________

Signature, company stamp: ________________________________________________________

9 Appendix

CVP High-Pressure Centrifugal Pump 37

Notes

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PUMPS

SYSTEMS
WATER TREATMENT
ENGINEERING
SERVICES

OSNA-Pumpen GmbH Your no. 1 choice for the solution you need:
Brückenstrasse 3
49090 Osnabrück, Germany - Consulting - Training
Phone: [phone] – 0 - Planning - Maintenance
Fax: [phone] – 220 - Project management - Repair
Internet: http://www.osna.de - Assembly
E-mail: [email protected]

OSNA customer service Tel.: [phone] – 254
Emergency service Tel.: [phone] – 674