OSNA LG 100, LG 200, LG 400, LG 500, LG 750 Original Operating Manual
Ver.16-08
Original Operating Manual
LG Piston 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
LG Piston Pump 1
Contents
1 GENERAL...................................................................................................................................5
1.1 About this operating manual..................................................................................................5
1.2 Target groups .......................................................................................................................5
1.3 Other valid documents ..........................................................................................................5
1.4 Warning notices and symbols................................................................................................6
1.5 Copyright/changes................................................................................................................6
2 SAFETY ......................................................................................................................................7
2.1 Correct and proper use .........................................................................................................7
2.2 General safety instructions....................................................................................................8
2.2.1 Product safety................................................................................................................8
2.2.2 Duties of the system owner ............................................................................................8
2.2.3 Duties of personnel ........................................................................................................9
2.3 Dangers of non-observance of the safety instructions..........................................................10
2.4 Unauthorized conversion and production of spare parts.......................................................10
2.5 Unauthorized modes of operation........................................................................................10
2.6 Special hazards ..................................................................................................................10
2.6.1 Explosion area.............................................................................................................10
2.6.2 Hazardous pumping media...........................................................................................10
2.6.3 Noise emissions...........................................................................................................10
3 LAYOUT AND FUNCTION ........................................................................................................11
3.1 Labeling..............................................................................................................................11
3.2 Scope of delivery, type LG piston pump ..............................................................................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 Storage...............................................................................................................................13
4.3 Intermediate storage...........................................................................................................14
4.4 Disposal..............................................................................................................................14
5 LAYOUT AND MODE OF OPERATION ....................................................................................15
5.1 Mode of operation...............................................................................................................15
5.2 Functional and operating elements......................................................................................15
5.3 Layout of the piston pump with pressurized container..........................................................16
5.4 Technical data ....................................................................................................................17
6 ASSEMBLY AND INSTALLATION............................................................................................18
6.1 Preparing for installation......................................................................................................18
2 LG Piston Pump
6.1.1 Checking the surrounding conditions............................................................................18
6.1.2 Preparing the installation location.................................................................................18
6.1.3 Preparing the base surface and foundations.................................................................18
6.2 Installation ..........................................................................................................................18
6.2.1 Installing the pump.......................................................................................................18
6.2.2 Electrical connection ....................................................................................................19
6.2.3 Water connection.........................................................................................................19
6.2.4 Assembling the piston pump with additional pressurized container ...............................20
6.3 Installation ..........................................................................................................................21
6.3.1 Installing the V-belt.......................................................................................................21
6.3.2 Belt guard ....................................................................................................................22
6.3.3 Installing the snifter valve .............................................................................................24
7 COMMISSIONING/ DECOMMISSIONING ................................................................................25
7.1 Preparing for commissioning...............................................................................................25
7.1.1 Determining the pump configuration.............................................................................25
7.1.2 Filling the drive casing with oil ......................................................................................25
7.2 Commissioning ...................................................................................................................26
7.2.1 Filling the pump............................................................................................................26
7.2.2 Checking direction of rotation .......................................................................................27
7.2.3 Starting the piston pump ..............................................................................................27
7.3 Decommissioning................................................................................................................29
7.4 Recommissioning................................................................................................................30
8 MAINTENANCE AND REPAIR..................................................................................................32
8.1 Maintenance.......................................................................................................................32
8.1.1 Oil level........................................................................................................................32
8.1.2 V-belt...........................................................................................................................33
8.1.3 Adding air ....................................................................................................................33
8.1.4 Stuffing box..................................................................................................................34
8.2 Maintenance service ...........................................................................................................34
8.2.1 Oil change....................................................................................................................35
8.2.2 Sending the pump to the manufacturer.........................................................................35
8.3 Safety valve........................................................................................................................35
9 FAULTS AND TROUBLESHOOTING........................................................................................37
10 APPENDIX.............................................................................................................................39
10.1 Service, spare parts, accessories ....................................................................................39
10.2 Individual parts of the LG piston pump.............................................................................40
10.3 Motor assembly...............................................................................................................44
10.4 Declaration of Conformity as per EC Directive 2006/42/EC, Annex IIA .............................46
10.5 Clearance Certificate.......................................................................................................47
LG Piston Pump 3
List of Tables
Table 1: Target groups and their tasks ................................................................................................5
Table 2: Other valid documents and their purposes............................................................................5
Table 3: Warning notices and consequences of non-observance.........................................................6
Table 4: Symbols and their meanings..................................................................................................6
Table 5: Starting torques...................................................................................................................12
Table 6: Technical data.....................................................................................................................17
Table 7: Measures in the event of operational interruption................................................................29
Table 8: Measures depending on the behavior of the pumping medium.............................................29
Table 9: Measures following longer shut down time...........................................................................31
Table 10: Measures for return ...........................................................................................................35
Table 11: Selection of SIOS valves ...................................................................................................36
Table 12: Fault causes......................................................................................................................38
Table 13: Parts list for the LG 100-400 piston pump ..........................................................................41
Table 14: Parts list for the LG 500-750 piston pump ..........................................................................43
Table 15: Motor assembly parts list for LG 100-400...........................................................................44
Table 16: Motor assembly parts list for LG 500-750...........................................................................45
4 LG Piston Pump
List of Images
Figure 1: Model code ........................................................................................................................11
Figure 2: Scope of delivery for type LG..............................................................................................11
Figure 3: Functional elements 1 ........................................................................................................15
Figure 4: Functional elements 2 ........................................................................................................15
Figure 5: Layout with pressurized container.......................................................................................16
Figure 6: Dimensions in front view.....................................................................................................17
Figure 7: Dimensions in side view .....................................................................................................17
Figure 8: Installation area side view...................................................................................................19
Figure 9: Installation area front view..................................................................................................19
Figure 10: Motor protection switch.....................................................................................................19
Figure 11: Water connection .............................................................................................................20
Figure 12: Assembly with pressurized container................................................................................20
Figure 13: Assembly with pressurized container................................................................................21
Figure 14: Tensioning the V-belt........................................................................................................21
Figure 15: Belt guard for LG 100 - 400 ..............................................................................................22
Figure 16: Assembling the belt guard for LG 500 and 750 ................................................................23
Figure 17: Removing the belt guard for LG 500 and 750....................................................................24
Figure 18: Snifter valve .....................................................................................................................24
Figure 19: Drive casing.....................................................................................................................25
Figure 20: Water side........................................................................................................................26
Figure 21: Starting the piston pump...................................................................................................28
Figure 22: Draining the pump............................................................................................................30
Figure 23: Oil level............................................................................................................................32
Figure 24: V-belt guard .....................................................................................................................33
Figure 25: Adding air.........................................................................................................................33
Figure 26: Stuffing box......................................................................................................................34
Figure 27: Oil change........................................................................................................................35
Figure 28: Safety valve .....................................................................................................................36
Figure 29: Explosion diagram of the LG 100-400 piston pump...........................................................40
Figure 30: Explosion diagram of the LG 500-750 piston pump...........................................................42
Figure 31: Explosion diagram of the LG 100-400 motor assembly .....................................................44
Figure 32: Explosion diagram of the LG 500-750...............................................................................45
1 General
LG Piston Pump 5
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 dimen-
sions, connection dimensions, etc.
Spare parts list Ordering spare parts
Clearance certificate Returning the pump
Declaration of conformity Conformity with
standards, content of
the declaration of conformity
Table 2: Other valid documents
and their purposes
1 General
6 LG Piston Pump
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
LG Piston Pump 7
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 water may not contain any abra-
sive 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.
• Never operate the pump when the armature on the delivery side is closed.
• 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 40 °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:
• Water supply to single-family and multiple-family homes
• Water supply to businesses and agriculture
• Sprinkling and irrigation of gardens
and other usable areas
The pump is self-priming after being filled
once with water.
Do not operate the pump without water. Dry
running can lead to damage to the pump.
Ensure that the foot valve is in the water at all
times.
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
8 LG Piston Pump
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
LG Piston Pump 9
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 (→ 7.2 Commissioning, pg 26).
• 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
10 LG Piston Pump
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 7).
Never exceed the limit values indicated in the
technical data
.
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 for a correctly installed and commissioned
LG piston pump is 70 dB(A).
3 Layout and function
LG Piston Pump 11
3 Layout and function
3.1 Labeling
This operating manual applies to pumps of the
LG 100 to LG 750 series.
Model code:
Figure 1: Model code
3.2 Scope of delivery, type LG piston pump
The customer can order the pump:
• in a preassembled state, i.e. delivery
without motor, accessories enclosed
unassembled. The motor is installed
by the customer.
• in a fully assembled state, i.e the
pump is fitted with motor ex-works.
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. If using other motor
brands, please ensure that the motors have
the following drive torques as a multiple of the
nominal torque.
Figure 2: Scope of delivery for type LG
Key:
1 Pump
2 Accessories (includes items 3 to 9, fully as-
sembled in complete version)
3 V-belt
4 Belt guard with holder and clamping set
5 V-role pulley key for motor shaft with lock
screw
6 Motor with motor fastening set
7 Snifter valve
8 Oil dipstick
9 Assembly and operating manual
LG 100
Size
OSNA - piston
pump with gear unit
3 Layout and function
12 LG Piston Pump
Motor power
Starting torque ratio
[kW]
Ms/Mn
Mn [Nm]
0.37 1.9 2.5
0.55 1.7 3.7
0.75 1.6 5.0
1.1 2.0 7.3
1.5 2.3 9.9
2.2 2.6 14.6
3.0 2.8 20.0
Table 5: Starting torques
Ms= Starting torque
M
n
= Nominal torque
kW = Kilowatt
Nm = Newton meter
List applies only to three-phase motors.
4 Transport and intermediate storage
LG Piston Pump 13
4 Transport and intermediate
storage
4.1 Transport
Weight information (→ Other valid documents)
NOTICE
Transport the pumps carefully and secure
them to prevent damage.
► Avoid applying pressure to the pump-side
V-role pulley key.
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.
4.2 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. Move the piston rod once per month.
4 Transport and intermediate storage
14 LG Piston Pump
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.
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.
4.3 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. (→ 7.3 Decommissioning, pg 29)
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 the oil and dispose of it in
line with the applicable local regulations.
–
Neutralize any pumping medium
residues in the pump.
► Dispose of the pump in line with the appli-
cable local regulations.
Loading...