VOGEL-Volute Casing Pumps
Installation, Operation and Maintenance Instruction
en
Model: LS, LC, LCP
Translation of the Original Operation Manual
Keep for further use !
en
Pay attention to this operating instruction before the delivery, installation, start-up a.s.o.!
Artikel Nr. 25-4265105 Rev. 02 01/2010
Xylem Water Solutions Austria GmbH
Ernst Vogel-Straße 2
A-2000 Stockerau
Telefon: +43 (0) 2266 / 604
Fax: +43 (0) 2266 / 65311
E-Mail:
Internet: www.xylemaustria.com
info.austria@xyleminc.com
Installation, Operating and Maintenance Instruction
TABLE of CONTENTS
Pump Name Plate ..................................................... 2
ATEX-Label (only for pumps in compliance with
EC directive 94/9/EG) ................................................ 2
1. General................................................................... 3
1.1 Guarantee ......................................................... 3
2. Safety Regulations ............................................... 3
2.1 Marking of References in the Operating
Instructions .............................................................. 3
2.2 Dangers of non-observance of the Safety
Instructions .............................................................. 4
2.3 Safety Instructions for the Operator / Worker ... 4
2.4 Safety Instructions for Maintenance, Inspections
and Mounting Work ................................................. 4
2.5 Unauthorized Alteration and Spare Parts
Production ............................................................... 4
2.6 Undue Operation ............................................... 4
2.7 Explosion Protection.......................................... 4
2.8 Use acc. to Regulations .................................... 6
3. Description ............................................................ 6
3.1 Design ............................................................... 6
3.2 Shaft Sealing ..................................................... 7
3.3 Bearings ............................................................ 7
3.4 Approximate Value for Sound Pressure Level .. 8
3.5 Permitted Nozzle Loads and Torques at the
Pump Nozzles ... ..................................................... 8
4. Transport, Handling, Storage .............................. 9
4.1 Transport, Handling ........................................... 9
4.2 Storage / Conservation.................................... 10
5. Mounting / Installation ....................................... 10
5.1 Mounting of Pump / Unit .................................. 10
5.2 Connection of Pipings to the Pump ................. 10
Model LS, LC, LCP
5.3 Coupling ........................................................... 11
5.4 Drive ................................................................ 12
5.5 Electric Connection .......................................... 13
5.6 Final Control .................................................... 13
6. Start-up, Operation, Shut down ......................... 13
6.1 Initial start-up ................................................... 13
6.2 Switch on drive ................................................ 13
6.3 Restarting ........................................................ 13
6.4 Limits of Operation .......................................... 14
6.5 Lubrication of Bearings .................................... 14
6.6 Monitoring ........................................................ 15
6.7 Shutting down .................................................. 15
6.8 Storage / longer periods of non-operation ....... 15
7. Servicing, Maintenance ...................................... 15
7.1 General remarks .............................................. 15
7.2 Mechanical seals ............................................. 16
7.3 Stuffing boxes .................................................. 16
7.4 Lubrication and Change of Lubricant ............... 16
7.5 Coupling ........................................................... 16
7.6 Cleaning of pump ............................................ 17
8. Dismantling and repair of pump ........................ 17
8.1 General remarks .............................................. 17
8.2 General ............................................................ 17
8.3 Disassembly of Back Pull Out Assembly ......... 17
8.4 Removal of Impeller ......................................... 18
8.5 Removal of Shaft Sealing ................................ 18
8.6 Removal of Bearing ......................................... 18
8.7 Reconditioning ................................................. 18
8.8 Mounting .......................................................... 19
9. Recommended Spare Parts, Spare Pumps ...... 20
9.1 Spare Parts ...................................................... 20
9.2 Stand-by pumps ............................................... 20
10. Faults - Causes and Solutions ......................... 20
LS 100-english page 1
Artikel No. 771073402
Revision 02
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Installation, Operating and Maintenance Instruction
Pump Name Plate
Model LS, LC, LCP
Type *) Type of pump
S/N *) Serial number
Year Year of construction
Q Rated capacity at the operating point
P Rated power at the operating point
H Head (Energy head) at the operating point
n Speed
p
all w C
t
max op
Item No Customer related order number
Max permitted casing-operation-pressure
(=highest discharge pressure at the rated
operating temperature to which the pump
casing can be used).
Maximum permitted operating temperature of
pumped liquid
*) All details of design and materials are defined with
this information. They must be stated on all inquiries to
the manufacturer resp. orders of spare.
Imp∅ Outer diameter of the impeller
ATEX-Label (only for pumps in compliance with EC directive 94/9/EG)
CE Marking of compliance with the EC directive
94/9/EG
Ex specific marking for explosion protection
II Symbol for the appliance group
2G Symbol for the category (2), explosive
atmosphere due to gases, vapours or mist (G)
c Symbol for used ignition protection
(constructive safety "c")
T1-T. Symbol for classification of the theoretically
available range of the temperature classes -
data for temperature class refer to chapter
2.7.5; Data for maximum permitted
temperature of pumped liquid refer to pump
name plate, data sheet and / or order
confirmation.
LS 100-english page 2
Artikel No. 771073402
The conformity with the EC directive 94/9/EG
"Appliances and Protection Systems for designated
use in areas endangered to explosion" is declared by
the issue of the EC-Declaration of Conformity and the
attachment of the ATEX-label at the pump (bearing
bracket). The ATEX-label is attached additionally to
the pump name plate.
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
The staff employed on installation, operation,
inspection and maintenance must be able to
evant
dent prevention regulations and that they
are suitably qualified for this work. If the staffs
do not have the relevant knowledge, they
observance can impair the pump and its
Products intended for use in explosive
1. General
Model LS, LC, LCP
This product corresponds with the requirements of the
Machine directive 2006/42/EG.
prove that they know about the rel
acci
should be provided with suitable instruction.
The operation safety of the delivered pump resp. unit
(= pump with motor) can only be guaranteed on
designated use according to the attached data sheet
and / or order confirmation resp. chapter 6 "Start-up,
Operation, Shut down".
The operator is responsible for following the
instructions and complying with the safety
requirements given in these Operating Instructions.
Smooth operation of the pump or pump unit can only
be achieved if installation and maintenance are carried
out carefully in accordance with the rules generally
applied in the field of engineering and electrical
engineering.
If not all the information can be found in these
Operating Instructions, please contact us.
The manufacturer takes no responsibility for the pump
or pump unit if the Operating Instructions are not
followed.
These Operating Instructions should be kept in a safe
place for future use.
If this pump or pump unit is handed on to any third
party, it is essential that these Operating Instructions
and the operating conditions and working limits given
in the Confirmation of Order are also passed on in full.
These Operating Instructions do not take into account
all design details and variants nor all the possible
chance occurrences and events which might happen
during installation, operation and maintenance.
We retain all copyright in these Operating Instructions;
they are intended only for personal use by the owner
of the pump or the pump unit. The Operating
Instructions contain technical instructions and
drawings which may not, as a whole or in part, be
reproduced, distributed or used in any unauthorised
way for competitive purposes or passed on to others.
1.1 Guarantee
The guarantee is given in accordance with our
Conditions of Delivery and/or the confirmation of
order.
Repair work during the guarantee period may only be
carried out by us, or subject to our written approval.
Otherwise the guarantee ceases to apply.
Longer-term guarantees basically only cover correct
handling and use of the specified material. The
guarantee shall not cover natural wear and tear and all
parts subject to wear, such as impellers, shaft sealing,
shafts, shaft sleeves, bearings, wear rings etc. or
damage caused by transport or improper handling.
In order for the guarantee to apply, it is essential that
the pump or pump unit is used in accordance with the
operating conditions given on the name plate,
confirmation of order and in the data sheet. This
applies particularly for the endurance of the materials
and smooth running of the pump and shaft sealing.
If one or more aspects of the actual operating
conditions are different, we should be asked to
confirm in writing that the pump is suitable.
2. Safety Regulations
These Operating Instructions contain important
instructions which must be followed when the pump is
assembled and commissioned and during operating
and maintenance. For this reason, these Operating
Instructions must be read by the skilled staff
responsible and/or by the operator of the plant before
it is installed and commissioned, and they must be left
permanently available at the place where the pump or
pump unit is in use.
These Operating Instructions do not refer to the
General Regulations on Accident Prevention or
local safety and/or operating regulations. The
operator is responsible for complying with these
(if necessary by calling in additional installation
staff).
Equally, instructions and safety devices regarding
handling and disposal of the pumped media and/or
auxiliary media for flushing, lubrication a.s.o.,
especially if they are explosive, toxically, hot a.s.o., are
not part of this operating instruction.
For the competent and prescribed handling only the
operator is responsible.
LS 100-english page 3
Artikel No. 771073402
2.1 Marking of References in the
Operating Instructions
The safety regulations contained in these Operating
Instructions are specially marked with safety signs
acc. to DIN 4844:
Safety reference!
Nonfunction.
EC-Ex Marking
atmospheres must be marked.
General Symbol for Danger!
Persons can be endangered.
Warning of electric voltage!
Safety instructions attached directly to the pump resp.
unit must be followed under any circumstances.
Further they must be kept in good readable condition.
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
On application of the unit in areas endangered
to explosion special attention must be paid to
During operation of the pump the system of the
suction and pressure pipe and the pump itself
must permanently be filled with the pumped
liquid. Thus, no explosive atmosphere can
If the operator can´t guarantee that, according
In the same way, as these Operating Instructions
of the pump, all possibly attached Operating
Instructions of accessories (e.g. motor) must be
noticed and kept available.
2.2 Dangers of non-observance of the
Safety Instructions
Non-observance of the Safety Instructions can
lead to loss of any claim for damages.
Further, non-observance can lead to following risks:
Failure of important functions of the machine or
facility.
Failure of electronic appliances and measuring
instruments by magnetic fields.
Endangering of persons and their personal
property by magnetic fields.
Endangering of persons by electric, mechanic and
chemical influences.
Endangering of environment through leakage of
dangerous substances.
sections marked with Ex.
2.3 Safety Instructions for the Operator /
Worker
Depending on the operating conditions, wear and
tear, corrosion or age will limit the working life of
the pump/pump unit, and its specified
characteristics. The operator must ensure that
regular inspection and maintenance are carried
out so that all parts are replaced in good time,
which would otherwise endanger the safe
operation of the system. If abnormal operation or
any damage is observed, the pump must cease
operation immediately.
If the breakdown or failure of any system or unit
could lead to people being hurt or property being
damaged, such system or unit must be provided
with alarm devices and/or spare modules, and
they should be tested regularly to ensure that they
function properly.
If there is any risk of injury from hot or cold
machine parts, these parts must be protected
against contact by the user, or suitable warning
signs must be affixed.
Contact protection on moving parts (e.g. coupling
guards) must not be removed from systems that
are in operation.
If the sound level of a pump or pump unit is above
85 dB(A) an ear protection has to be used when
staying near the pump for some time.
If dangerous media (e.g. explosive, toxic, hot) leak
out (e.g. from shaft seals), these must be directed
away so that there is no danger to people or the
environment. The provisions of the law must be
observed.
Measures should be taken to exclude any danger
from electricity (e.g. by complying with the local
regulations on electrical equipment). If work is
carried out on live electrical components, they
LS 100-english page 4
Artikel No. 771073402
Model LS, LC, LCP
should be unplugged from the mains or the main
switch turned off and fuse unscrewed. A motor
protection switch is to be provided.
2.4 Safety Instructions for Maintenance,
Inspections and Mounting Work
The operator is responsible that any maintenance,
inspections and mounting work is made by
authorized competent personnel, which must be
informed by having read the Operating
Instructions.
Basically, all work on the pump or pump unit
should only be carried out when the pump is
stationary and not under pressure. All parts must
be allowed to return to ambient temperature.
Make sure that no-one can start the motor during
such work. It is essential that the procedure for
stopping the system described in the Operating
Instructions is observed. Pumps or pump systems
that carry media that are dangerous to health must
be decontaminated before being taken apart.
Safety Data Sheets for the various liquids handled.
Immediately after finishing work, all safety and
protective devices must be replaced or restarted.
2.5 Unauthorized Alteration and Spare
Parts Production
Alteration or changes of the machine are permitted
after agreement with the manufacturer.
Original spare parts and accessory authorized by the
manufacturer are serving the safety.
The use of other parts can lead to loss of liability for
there from resulting consequences.
2.6 Undue Operation
The operating safety of the delivered machine can
only be guaranteed by designated use acc. to the
following chapters of the Operating Instructions. The
limits stated in the data sheet and / or order
confirmation must not be exceeded under any
circumstances.
2.7 Explosion Protection
On application of units in areas endangered to
explosion measures and references in the chapters
2.7.1 to 2.7.6 must be observed, so that explosion
protection is guaranteed.
2.7.1 Filling of unit
develop and the danger of dry-run is avoided.
monitoring measures must be provided.
Issue 01/2010
Revision 02
Installation, Operating and Maintenance Instruction
Equally all seal casings, auxiliary systems of the
shaft sealing, as well as heating and cooling
The marking of the pump refers to the pump
itself. For coupling and motor resp. further
tions a separate Declaration of Conformity,
as well as a corresponding marking must be
Carry out rotation control with separated
pling halves only! Refer to chapter 5.5 and
If danger of explosion is also existing during
tion control must not be
up of the empty pump,
to avoid undue temperature increase in case of
There’s a danger, that high surface
tures are developing at the pump
casing after relatively short time, through fast
side the pump can
On pumps with mech. seals the permitted
run. Dry run not only can occur on insufficiently
but also because of too much
Operation of the pump out of the permitted
Under normal operating conditions the highest
e
of the pump casing and in the area of the
If the pump is heated (e. g. heating jacket), care
s,
During operation of the pump it must be
cured that an overabundant sedimentation of
g), to prevent
heating of pump surface over the permitted
The particular allowed operating temperature of
the pump is shown in the data sheet and / or the
order confirmation resp. the type plate at the
For a secure and reliable operation it must be
secured by regular inspections, which the unit is
and is kept in good
systems must be filled carefully.
2.7.2 Marking
addi
available.
Example of of marking at pump:
CE Ex II 2 G c T... .
The marking shows the theoretically applicable range
of temperature classes. The different temperatures,
permitted acc. to pump design, result as shown in
chapter 2.7.5. The same is valid for the drive.
For a whole unit (pump, coupling, motor) with different
temperature classes the lowest is valid.
2.7.3 Rotation Control
cou
6.1 as well.
installation, the rota
carried out by short start-
contact of rotating and stationary parts.
2.7.4 Operation of pump
The pump must only be started up with fully opened
suction side and slightly opened pressure side valve.
The start-up against closed non-return valve, however,
is possible. Immediately after the start-up the
discharge side valve must be adjusted to the operating
point.
Refer to chapter 6.2, as well.
Operation with closed valve in suction and / or
discharge pipe is not permitted!
tempera
Model LS, LC, LCP
temperature limits can be exceeded due to dry-
filled seal casing,
gas in the medium.
operating range can lead to dry-run, as well.
2.7.5 Temperature Limits
temperatures must be expected at the surfac
bearings.
The surface temperature occurring at pump casing
corresponds with the temperature of the pumped
liquid.
must be taken, that the temperature classe
prescribed for the plant are observed.
In the area of the bearing bracket free contact from
surface to surrounding must be given.
se
dust is avoided (regular cleanin
temperature.
The operator of the plant must secure that the
defined operating temperature is observed. The
max. allowed temperature of the pumped liquid at
suction depends on the particular temperature
class.
The following table shows the theoretical temperature
limits of the pumped liquid in consideration of the
temperature classes acc. to EN 13463-1.
Temperature class acc.
EN 13463-1
T4 (135°C) 135°C
T3 (200°C) 180°C
T2 (300°C) 180°C
T1 (450°C) 180°C
Temperature limit of
pumped liquid
heating of the liquid inside the pump.
Fast pressure increase in
lead to overload and, thus, the pump can burst.
In chapter 6.4.1 the minimum flow is stated. Longer
operating phases with these flows and the named
liquids don’t cause additional increase of surface
temperature at the pump.
Furthermore the references in chapter 6 of these
operating Instructions must be taken into
consideration.
LS 100-english page 5
Artikel No. 771073402
pump.
In the area of the bearings the temperature class T4 is
guaranteed, provided that the ambient temperature is
40°C and the appliance is duly operated and
maintained.
2.7.6 Maintenance
maintained competently
technical condition.
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
Electric switches and control devices,
mentation and accessories like e.g. flush
.s.o., must correspond with the valid
safety requirements and regulations for
Suitable safety measures must be taken at the
and
temperature of the pump and the shaft sealing
do not exceed the limit values given in the data
sheet and / or order confirmation. The given
admission pressures (system pressures) must
Basically the suction and discharge piping must
be designed in such way, that as little forces as
possible are effective to the pump. If that is not
r 3.5 must
not be exceeded under any circumstances. This
is valid for the operation as well as for the
standstill of the pump and therefore for all
sible pressures and temperatures of the
The pumped liquid must have a min. pressure
NPSH at the impeller inlet; so that cavitations
free work is secured resp. a "break off" of the
pump flow is prevented. This condition is
value of the system
value of the pump
Example: Function of bearings. Operation and
application conditions are essentially responsible for
their achievable life cycle.
By regular control of the lubricant and the running
sound the danger of occurring over temperatures by
bearings running hot or defect bearing seals is
avoided. Refer to chapter 6.6 and 7.4.
The function of the shaft sealing must be secured by
regular control.
If auxiliary systems (e.g. external flushing, cooling,
heating) are installed, it must be checked, if monitoring
devices are necessary to secure the function.
2.7.7 Electric switches and control device,
Instrumentation and accessories
instru
tanks, a
explosion protection.
2.8 Use acc. to Regulations
2.8.1 Speed, Pressure, Temperature
plant to ensure that the speed, pressure
also be sufficiently high.
Further, pressure shocks, as can occur on too fast
shut down of the facility, must be kept away from the
pump (e.g. by non-return valve at pressure side, fly
wheel, air tanks). Quick temperature changes must be
avoided. They could cause a temperature shock and
lead to damage or impair the function of single
components.
2.8.2 Permitted Nozzle Loads and Torques
Model LS, LC, LCP
2.8.3 NPSH
fulfilled, when NPSH(NPSHA) lies above NPSH(NPSHR) under all operating conditions.
Attention must especially be paid to the NPSH-value
on pumping liquids near the vapour pressure. If the
NPSH-value of the pump remains under, this can lead
from damage of the material due to cavitations to
destruction by overheating.
The NPSH-value of the pump (NPSHR) is shown in
the curves of every pump type.
2.8.4 Sealing, Flushing, Cooling
Suitable provisions for the regulation and monitoring of
sealing, flushing or cooling are to be provided.
When handling dangerous liquids or if temperatures
are high, care should be taken to ensure that the
pump ceases operating if the sealing, flushing or
cooling system fails.
Sealing, flushing and cooling systems must always be
operational before the pump is started up. They
should not be taken out of operation until the pump
has stopped, provided that the nature of the operation
allows this at all.
2.8.5 Back Flow
In systems where pumps are operating in closed
circuits under pressure (gas cushions, steam
pressure), the pressure of the gas cushion must not
be reduced via the pump, since the back flow speed
may be much higher than the operating speed, which
would destroy the unit.
possible, the values shown in chapte
pos
unit.
3. Description
3.1 Design
LS-Pumps are single stage volute-casing pumps with
closed impeller in process design; they are in
accordance with the technical specifications of ISO
5199 / EN 25199.
LC-Pumps as model LS, but qualified for higher
casing pressure.
LS 100-english page 6
Artikel No. 771073402
LCP-Pumps as model LC, but with casing feet in
centre line.
The pumps are designed as modular systems and
can, therefore, be delivered in many variants (e.g.
different materials, shaft sealing, different kinds of
lubrication, cooling / heating, a.s.o.).
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
Further details about packing and mech. seals,
as well as the therewith connected accidental
dangers, you can find in chapter 6.6 and in
o explosion the use of
In areas endangered to explosion the use of
pumps with grease lubricated bearings is
The permitted application conditions and design
details of the delivered pump are shown in the
attached data sheet and / or order confirmation.
3.1.1 Designation scheme
The permitted application conditions and design
details of the delivered pump are shown in the
attached data sheet and / or order confirmation.
For example:
LS 200 - 500 S1 N L 1 2500 4
(0) (1)
Position (0) - Model designation:
LS - Foot mounted casing design (12 / 16 bar)
LC - Foot mounted casing design (25 bar)
LCP - Casing feet centre line (25 bar)
Position (1) - Nominal diameter of discharge nozzle in
mm
Position (2) - Nominal impeller size in mm
Position (3) - Method of shaft sealing:
S1 - Single mechanical seal acc. EN 12756,
design K, form U (unbalanced)
S2 - Single mechanical seal acc. EN 12756,
design K, form B (balanced)
S4 - Single mechanical seal acc. EN 12756,
design K, form U (unbalanced), with Quench (with
throttle bush)
S5 - Single mechanical seal acc. EN 12756,
design K, form B (balanced), with Quench (with
throttle bush)
S6 - Single mechanical seal acc. EN 12756,
design K, form U (unbalanced), with throttle
(throttle bush) between pump and mechanical
seal chamber
S7 - Single mechanical seal acc. EN 12756,
design K, form B (balanced), with throttle (throttle
bush) between pump and mechanical seal
chamber
T3 - Single mechanical seal acc. EN 12756,
design K, form B (balanced), in dead-endconfiguration with extended throttle bush
D1 - Double mechanical seal back-to-back, 2
single mechanical seals acc. EN 12756, design K,
both form U (unbalanced)
D3 - Double mechanical seal back-to-back, 2
single mechanical seals acc. EN 12756, design K,
on fluid side form U (unbalanced), atmospheric
side form B (balanced)
C1 - Cartridge mechanical seal on pump sleeve
C3 - Cartridge mechanical seal on the shaft
P1 - Packing without lantern ring
P2 - Packing with lantern ring, with barrier by
pumped fluid
P3 - Packing with lantern ring, with barrier by
external fluid
P4 - Packing with lantern ring, with flush
P5 - Packing without lantern ring, with external
cooling
Position (4) *) - Material of impeller:
N = Cast iron (0.6025)
S = Bronze (2.1050.01) - only at model LS
L = Ductil iron (0.7040)
V = Stainless steel (1.4408)
LS 100-english page 7
Artikel No. 771073402
(2) (3) (4) (5) (6) (7) (8)
Model LS, LC, LCP
W = Duplex stainless steel (1.4517)
F = Carbon steel (1.0619)
X = Other materials
Position (5) *) - Material of casing:
N = Cast iron (0.6025)
L = Ductil iron (0.7040)
V = Stainless steel (1.4408)
W = Duplex stainless steel (1.4517)
F = Carbon steel (1.0619)
X = Other materials
Position (6) - Shaft design:
1 - with shaft sleeve
2 - without shaft sleeve
Position (7) - Motor power in 1/10 kW
Only valid, if supplied (eg. 2500 = 250 kW)
Position (8) - Number of motor poles
Only valid, if supplied
*) Position (4) and (5) = Material-Code (eg. NL, VV,
WW aso.)
3.2 Shaft Sealing
Basically there are two kinds of shaft sealing: the
packing and the mechanical seal, whereas, there
again are many variants of both kinds. At the data
sheet and / or the order confirmation the shaft sealing
type of your pump is shown.
An instruction for the packing of a stuffing box resp.
for the mounting and operation of mech. seals can be
found in the appendix of the particular "Mounting
Instructions of the Shaft Sealing".
chapters 7.2 and 7.3.
In areas endangered t
pumps with packing is forbidden!
3.3 Bearings
The pump shaft is guided by antifriction bearings. In
the data sheet and / or order confirmation you can
see, if your pump is designed for oil lubrication
(standard design) or grease lubrication (special
design).
forbidden!
3.3.1 Used bearings
The size of the bearing bracket of your pump is shown
in the data sheet and / or order confirmation.
Bearing bracket
pump side drive side
Bearing type
42 S NU 311 EC 2x 7311 BECB
55 S NU 315 EC 2x 7315 BECB
75 S, 90 S NU 320 EC 2x 7320 BECB
100 S NU 324 EC 2x 7324 BCB
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
3.3.2 Oil Sump Cooling
On temperatures of the pumped liquid over 180°C an
oil sump cooling is required.
For connection refer to list "Connections" in the annex.
For cooling use pure, non-aggressive water with a
maximum incoming temperature of 30°C.
Cooling water should be hand-warm at discharge.
The pressure in the cooling system must not
exceed max. 6 bar.
Provide control devices for temperature and
pressure monitoring.
3.4 Approximate Value for Sound
Pressure Level
Nominal
power
PN
in kW
5,5 -- 61,0 - - - - 64,0 - -
7,5 -- 63,0 - - - - 64,5 - 11,0 -- 65,0 - - - - 66,0 - 15,0 -- 66,5 - - - - 67,5 - 18,5 68,5 68,0 - - 69,0 69,0 - 22,0 69,5 68,5 - - 70,0 69,5 - 30,0 71,0 70,5 - - 71,5 71,0 - 37,0 72,0 71,5 - - 73,0 72,0 - 45,0 73,0 72,5 - - 74,0 73,5 - 55,0 74,5 73,5 - - 75,0 74,5 - 75,0 76,0 75,5 - - 76,5 76,5 - 90,0 77,0 76,5 - - 77,5 77,5 - -
110,0 78,0 77,5 77,0 79,0 78,5 80,0
132,0 79,0 78,5 78,0 79,5 79,5 80,0
160,0 80,0 79,5 79,0 80,5 81,0 80,5
200,0 81,5 81,0 80,5 81,5 82,0 83,0
250,0 82,5 82,0 81,5 84,5 83,0 84,0
315,0 83,5 83,0 83,0 85,0 85,5 84,5
355,0 84,5 84,0 - - 85,5 86,0 - 400,0 85,0 84,5 - - 88,0 86,5 - 450,0 -- 85,0 - - - - 87,0 - 500,0 -- 85,5 - - - - 87,0 - -
Sound pressure level LpA measured in 1 m distance
from pump surface acc. to DIN 45635, part 1 and 24.
Room and foundation influences are not considered.
The tolerance for these values is ±3 dB(A).
Addition with 60 Hz-operation:
Pump alone: −
Pump with motor: +4 dB(A)
2950
rpm
Sound pressure level LpA in dB(A)
Pump alone Pump + Motor
1450
rpm
975
rpm
2950
rpm
1450
rpm
975
rpm
Model LS, LC, LCP
3.5 Permitted Nozzle Loads and Torques
at the Pump Nozzles ...
... following the Europump-Recommendation for
pump acc. to ISO 5199.
The data for forces and torques are only valid for static
piping loads.
The values given in the chart are valid for pump units
with standard LS- or LCP-base frames (grouted).
The data for forces and torques refer to LC or LCPstandard materials 0.7040 (ductil iron) and 1.4408
(stainless steel).
For the LS-standard material 0.6025 (cast iron) the
values must be multiplied with factor 0,5.
LS, LC
pic 1
LCP
LS 100-english page 8
Artikel No. 771073402
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
Dispose of all packing materials in accordance
with local regulations.
Take note of the general regulations on
The pump / pump unit must be secured against
tipping over and slipping until it has been fixed
ts
Model LS, LC, LCP
Sizes
∅DN
Forces in N Torques in Nm
Fx Fy Fz
125-330 150 4000 3600 3240 6280 2000 1400 1640 2920 125 2840 2560 3160 4960 1680 1200 1520 2440
125-500 150 4000 3600 3240 6280 2000 1400 1640 2920 125 2840 2560 3160 4960 1680 1200 1520 2440
150-500 200 5360 4800 4320 8360 2600 1840 2120 3840 150 3600 3240 4000 6280 2000 1400 1640 2920
200-260 250 6680 5960 5400 10440 3560 2520 2920 5240 200 4800 4320 5360 8360 2600 1840 2120 3840
200-350 250 6680 5960 5400 10440 3560 2520 2920 5240 200 4800 4320 5360 8360 2600 1840 2120 3840
200-400 250 6680 5960 5400 10440 3560 2520 2920 5240 200 4800 4320 5360 8360 2600 1840 2120 3840
200-500 250 6680 5960 5400 10440 3560 2520 2920 5240 200 4800 4320 5360 8360 2600 1840 2120 3840
250-315 300 8000 7160 6440 12520 4840 3440 3960 7120 250 5960 5400 6680 10440 3560 2520 2920 5240
250-350 300 8000 7160 6440 12520 4840 3440 3960 7120 250 5960 5400 6680 10440 3560 2520 2920 5240
250-400 300 8000 7160 6440 12520 4840 3440 3960 7120 250 5960 5400 6680 10440 3560 2520 2920 5240
250-500 300 8000 7160 6440 12520 4840 3440 3960 7120 250 5960 5400 6680 10440 3560 2520 2920 5240
300-400 350 9320 8360 7520 14600 6200 4400 5080 9120 300 7160 6440 8000 12520 4840 3440 3960 7120
300-450 350 9320 8360 7520 14600 6200 4400 5080 9120 300 7160 6440 8000 12520 4840 3440 3960 7120
300-500 350 9320 8360 7520 14600 6200 4400 5080 9120 300 7160 6440 8000 12520 4840 3440 3960 7120
350-450 400 10640 9560 8600 16680 7760 5520 6360 11440 350 8360 7520 9320 14600 6200 4400 5080 9120
400-400 400 10640 9560 8600 16680 7760 5520 6360 11440 400 9560 8600 10640 16680 7760 5520 6360 11440
600-600 600 15920 14360 12920 25000 16160 11520 13280 23920 600 14360 12920 15920 25000 16160 11520 13280 23920
125-500 150 5000 4500 4050 7850 2500 1750 2050 3650 125 3550 3200 3950 6200 2100 1500 1900 3050
150-500 200 6700 6000 5400 10450 3250 2300 2650 4800 150 4500 4050 5000 7850 2500 1750 2050 3650
200-260 250 8350 7450 6750 13050 4450 3150 3650 6550 200 6000 5400 6700 10450 3250 2300 2650 4800
200-350 250 8350 7450 6750 13050 4450 3150 3650 6550 200 6000 5400 6700 10450 3250 2300 2650 4800
200-400 250 8350 7450 6750 13050 4450 3150 3650 6550 200 6000 5400 6700 10450 3250 2300 2650 4800
200-500 250 8350 7450 6750 13050 4450 3150 3650 6550 200 6000 5400 6700 10450 3250 2300 2650 4800
250-315 300 10000 8950 8050 15650 6050 4300 4950 8900 250 7450 6750 8350 13050 4450 3150 3650 6550
250-350 300 10000 8950 8050 15650 6050 4300 4950 8900 250 7450 6750 8350 13050 4450 3150 3650 6550
250-400 300 10000 8950 8050 15650 6050 4300 4950 8900 250 7450 6750 8350 13050 4450 3150 3650 6550
250-500 300 10000 8950 8050 15650 6050 4300 4950 8900 250 7450 6750 8350 13050 4450 3150 3650 6550
300-400 350 11650 10450 9400 18250 7750 5500 6350 11400 300 8950 8050 10000 15650 6050 4300 4950 8900
300-450 350 11650 10450 9400 18250 7750 5500 6350 11400 300 8950 8050 10000 15650 6050 4300 4950 8900
300-500 350 11650 10450 9400 18250 7750 5500 6350 11400 300 8950 8050 10000 15650 6050 4300 4950 8900
350-450 400 13300 11950 10750 20850 9700 6900 7950 14300 350 10450 9400 11650 18250 7750 5500 6350 11400
400-400 400 13300 11950 10750 20850 9700 6900 7950 14300 400 11950 10750 13300 20850 9700 6900 7950 14300
600-600 600 19900 17950 16150 31250 20200 14400 16600 29900 600 17950 16150 19900 31250 20200 14400 16600 29900
Suction nozzle Discharge nozzle
Mx My Mz
F
M
∅DN
Forces in N Torques in Nm
Fx Fy Fz
Mx My Mz
F
LS, LC
LCP
M
4. Transport, Handling, Storage
4.1 Transport, Handling
Check the pump / pump unit immediately upon
delivery / receipt of despatch for damage or
missing parts.
The pump / pump unit must be transported
carefully and by competent personnel. Avoid
serious impacts.
Keep the pump/pump unit in the same position in
which it was supplied from the factory. Take note
of the instructions on the packaging.
The suction and discharge side of the pump must
be closed with plugs during transport and storage.
Lifting devices (e.g. fork-lift truck, crane, crane
device, pulleys, sling ropes, etc.) must be
sufficiently strong and must only be used by
authorized persons. The weight of the pump /
pump unit is given in the data sheet.
The pump / pump unit may only be lifted by solid
points such as the casing, flanges or frame.
Picture 2 shows the correct method of carrying by
crane.
pic 2
Do not stand underneath suspended loads.
prevention of accidents.
in its final location.
Sling ropes must not be fixed to ends of shaf
or the ring loops of the motor.
LS 100-english page 9
Artikel No. 771073402
Issue 01/2010
Revision 02
Installation, Operating and Maintenance Instruction
Slipping out of the pump / pump unit of the
port lifting device can cause damages to
Sufficient space must be provided for
nance and repair work, especially for
replacing the drive motor or the complete pump
The motor fan must be able to take in
enough cool air, and the intake grille must
therefore be at least 10 cm away from any wall,
The size of these insulating pads will vary,
ding on circumstances, and should
fore be determined by an experienced
trans
persons and things.
4.2 Storage / Conservation
Pumps or units, which are stored over a longer period
before start-up (max. 6 months), must be protected
from moisture, vibrations and dirt (e.g. by wrapping in
5. Mounting / Installation
Model LS, LC, LCP
oil paper or plastic). Pumps must basically be stored in
a place where they are protected from the weather,
e.g. under dry cover. During this time, all suction and
discharge branches and all other intakes and outlets
must be closed with dummy flanges or plugs.
For longer periods of storage conservation
measurements at machined surfaces and packing with
moisture protection can be necessary!
5.1 Mounting of Pump / Unit
5.1.1 Mounting of pump on a base frame
The pump and motor (= pump unit) must be provided
with a base frame made of steel or cast iron or a
fabricated (welded) frame, where this does not exist
already or if it is not included in the delivery. This base
frame must be placed on a foundation which can
withstand all loads that arise during operation (refer to
chapter 5.1.2).
When mounting the pump onto the base frame the
following must to be noticed:
The base frame must be solid, so that there won’t
occur any twists or vibrations during the operation.
The mounting surfaces of the pump feet and
motor on the base frame must be flat (machining
is recommended). Bracing of the pump leads to
premature breakdown of the pump and to a loss of
warranty.
The drillings for the pump mounting must be in
such a way, that safe fastening is guaranteed.
Between pump and motor shaft an adequate
space must be left depending on the used
coupling, refer to chapter 5.3.
Between pump and base frame there must be an
adequate shimming, so that in the case of
replacement of the pump the equal height
between bottom and centreline can be adjusted
(recommended vertical adjustment 4 to 6 mm).
Align pump and motor, refer to chapter 5.3, as
well.
5.1.2. Mounting the unit to a foundation
The place, where the pump is mounted must be
prepared acc. to the dimensions of the dimensional
drawings. The concrete foundations should have
sufficient firmness acc. to DIN 1045 or equal standard
(min. BN 15), to ensure a secure, functional mounting.
The concrete foundation must have set, before the
unit is erected. Its surface must be horizontal and
even.
mainte
unit.
etc.
For the set of anchor bolts according recesses
must be provided. If that is not the case, concrete
expansion bolts resp. epoxy capsule anchor bolts
can be used.
When mounting the pump on the foundation it
must be adjusted at the discharge nozzle by
means of a spirit-level (at discharge nozzle). The
permitted deviation is 0,2 mm/m. After inserting
the foundation bolts they must be cast in the
foundation with concrete. After setting of the grout
the coupling alignment must be checked
according chapter 5.3.1 and possible
misalignments must be corrected by adjusting
foundation frame in the area of the drive motor.
The smoothness of the base frame must be 0,2
mm/m before it is filled up resp. fastened. For
adjustment levelling shims or levelling screws
(optional, not delivered standard wise) can be
used. Levelling shims must be inserted next to the
foundation anchors and must lie plainly. After that
fasten foundation bolts symmetrically but only
slightly. Fill in base frame with non shrinking grout.
Notice:
Avoid air bubbles (e.g. by vibrating).
Check that the grout has properly set and
hardened.
Take care for the after-treatment of the concrete
acc. to DIN 1045.
After setting, tighten the foundation anchor evenly and
firmly. Check alignment of coupling acc. to chapter
5.3.1 and re-adjust, if necessary. Further, check that
all screws between pump / motor and the base frame
fit snugly.
Although the original LS- resp. LCP-base frames are
designed solidly, the grouting of the adjusted base
frames is absolutely necessary.
If vibrations are transmitted to the foundation from
adjoining components, it must be guarded through
adequate vibration damping padding (vibrations
from outside can impair the bearing).
To prevent vibrations being transmitted to
adjoining components, the foundation should be
laid on a suitable insulating base.
depen
there
specialist.
LS 100-english page 10
Artikel No. 771073402
Revision 02
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Installation, Operating and Maintenance Instruction
The pump must not be used as fixed point for
the piping. The permitted piping loads must not
These connections are essential for the
Make sure that nobody can start the motor
According to Accident Prevention Regulations,
the pump unit may only be operated when the
h
The alignment of the coupling must be carried
out with the utmost care and attention, so that
without failure. If you do not
pay attention to this hint you will lose your
wa
After mounting onto the foundation and the
connection of the piping the coupling must be
adjusted again, even, if the unit was delivered
5.2 Connection of Piping to the Pump
be exceeded, refer to chapter 3.5.
5.2.1 Suction and discharge pipe
The pipes must be of a size and design that liquid
can flow freely into the pump and that the pump
functions without problems. Particular attention is
to be paid to ensuring that suction pipes are
airtight and that the NPSH values are observed.
Under suction lift condition lays the suction pipe in
the horizontal section towards the pump so that it
is slightly inclined upwards so that no air traps
occur. Under positive suction head condition
install the suction pipe work slightly declined
towards the pump. Do not install fittings or elbows
right before the suction nozzle.
If the suction supply is under vacuum and
entrained gas may be present in the liquid, it is
recommended that a vent line be considered
upstream of the pump suction with return to the
suction supply, above the max liquid level.
An additional flushed piping - discharge branch-
vent line - makes it easier to de-aerate the pump
before start-up (pic 3).
Model LS, LC, LCP
If the pipe system is tested with the pump
installed, do not exceed the maximum permitted
casing pressure of the pump and/or shaft sealing
(see data sheet).
When emptying the pipe after the pressure test,
make sure that the pump is treated properly
(danger of rust and problems when starting up).
In the case of pumps with stuffing boxes, replace
packing after pressure test (packing may be overcompressed and thus no longer suitable for use).
5.2.2 Additional connections
Any required sealing, flushing or cooling pipe
connections must be installed. Please consult the data
sheet to see which pipes, pressures and amounts are
necessary. The position and size of connections to the
pump are given in the appendix, "Connections".
function!
It is recommended that a pipeline is installed to take
off any leakage from the shaft seal. For connection,
see appendix, "Connections".
5.3 Coupling
during work on the coupling.
pic 3
When laying the pipes, make sure that the pump
is accessible for maintenance, installation and
disassembly.
Notice "Permitted Forces on Flanges" (chapter
3.5).
If expansion joints are used in the pipes, they
have to be supported in such a way that the pump
is not loaded unduly high because of the pressure
in the pipes.
Before connecting up to pump: remove protective
coverings from suction and discharge branches.
Before starting up, the pipe system, fittings and
equipment must be cleaned to remove weld
spatter, scale etc. Any pollutants are to be
completely removed from pump units that are
directly or indirectly connected to drinking water
systems before being installed and taken into use.
To protect the shaft sealing (especially mechanical
seals) against foreign impurities, it is
recommended that a sieve, 800 micron, is
installed in the suction/intake pipe when the motor
is being started up.
LS 100-english page 11
Artikel No. 771073402
coupling guard is mounted.
On operation in zone 1 and 2 a coupling wit
valid Atex-certification must be used.
The Operating Instructions of the manufacturer
must be followed.
5.3.1 Alignment of coupling
the unit will operate
rranty!
completely mounted on the frame.
Before starting installation, carefully clean shaft
ends and coupling components.
Before adjusting the coupling unfasten screws
(S7) between bearing bracket (10) and casing foot
(80/F) and only fasten again after the adjustment.
Repeat measurement after fastening of screws
(S7).
The unit is properly aligned, when a ruler, which is
laid axially over both coupling halves, has the
same distance to the particular shaft everywhere
on the circumference. Further, both coupling
halves must have the same distance to one
another on every of the circumference. This must
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
Control alignment of coupling again in operation
warm conditio
n and on system pressure (if
available) and correct, if necessary. Pay
tion to chapter 6 beforehand! It must be
ble to turn the unit easily and harmoniously
Improper alignment of the unit can lead to
Mount coupling guard after alignment and
Acc. to accident prevention regulations the
pump must only be operated with coupling
Care has to be taken, that the used coupling
a motor with
be checked by means of a tracer, gauge or dial
gage; refer to pic. 4 and 5.
The permitted tolerances for your coupling are
shown in the operating instructions of the
coupling. For the exact characterization of your
coupling refer to data sheet and / or order
confirmation.
Model LS, LC, LCP
Assembly:
ruler
gauge
pic 4 - Alignment of coupling with gauge and ruler
ruler
pic 5 - Alignment of coupling with spacer
gauge
atten
possi
by hand.
damages at coupling and unit!
before start-up.
5.3.2 Coupling Guard
guard.
Parts:
LS 100-english page 12
Artikel No. 771073402
guard consists of non-sparking material.
5.4 Drive
On selecting the motor size care has to be taken, that
the requirements acc. to ISO 5199 are fulfilled. Note
the Operating Instructions of the motor
manufacturer.
On application in zone 1 and 2
valid Atex-certification must be used.
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
Electrical connection work may only be carried
out by an authorised professional. The rules
and regulations valid for electrical technology,
safety
ures, must be observed. The regulations
of the national power supply companies
14
ticed for the electric
Care must be taken that the base frame (2x
thread available for earthing screws) is
The direction of rotation must only be checked
when the pump is full. Dry runni
ng will cause
eople who
are familiar with the local safety regulations and
with these Operating Instructions (especially
with the safety regulations and safety
Operation with closed valve in the suction and /
pressure must be produced through throttling at
In order that the shaft sealing can be monitored
maintained unhindered, no protection cover
is provided in this area. Therefore special
tion is required when pump is working (no
Dry running packing harden and destroy the
If pump does not reach attended head or if
Switch off pump (see chapter 6.7) and seek for
5.5 Electric Connection
especially those concerned with
meas
Model LS, LC, LCP
In areas endangered to explosion IEC 60079must additionally be no
installation.
M10earthed by means of corresponding measures.
operating in that area must also be observed.
Before starting work, check that the information on the
motor name plate is the same as the local mains
network. The power supply cable of the coupled drive
motor must be connected up in accordance with the
wiring diagram produced by the motor manufacturer. A
protective motor switch must be provided.
6. Start-up, Operation, Shut down
The plant may only be started up by p
instructions given here).
6.1 Initial start-up
Before starting up the pump, check, if the following
points were controlled and carried out:
If pump is oil lubricated, first open oil drain (AS)
and drain off any liquid that may have collected
(e.g. condensation). Close oil drain (AS) and fill oil
as described in chapter 6.5.1.
For pumps with grease lubrication, no further
lubrication is needed before initial start-up.
Pump and suction pipe must be filled completely
with liquid when starting up.
Turn pump unit once again by hand and check
that it moves smoothly and evenly.
Check that coupling guard is installed and that all
safety devices are operational.
Switch on any sealing, flushing or cooling devices
that are provided. See data sheet for quantity and
pressure.
Open valve in suction /intake pipe.
Set discharge side valve to approx. 25% of rated
flow quantity. With pumps with a discharge branch
rated width less than 200, the valve can remain
closed when starting up.
Secure, that unit is electrically connected acc. to
all regulations and with all safety devices.
Check direction of rotation by switching on and off
briefly. It must be the same as the directional
arrow on the bearing frame.
6.2 Switch on drive
Immediately (max. 20 seconds on 50 Hz resp.
max. 11 seconds on 60 Hz currency feed) after
reaching normal operating speed open discharge
valve adjust the required operating point. The
pumping data shown at the type plate resp. in the
data sheet and / or the order confirmation must be
LS 100-english page 13
Artikel No. 771073402
damage to the pump.
5.6 Final Control
Check alignment of coupling acc. to chapter 5.3.1
again. It must be possible to turn the unit easily by
hand at the coupling.
met. Every change is only permitted after talking
with the manufacturer!
or discharge piping is not permitted.
On starting-up without back-pressure, the back-
the discharge side. After reaching full backpressure open valve
and
atten
long hair, loose clothes, a.s.o.).
Packing:
Packing needs leakage for trouble free function
(drop wise outlet of the pumped medium). Adjust
ample leakage in the beginning. Reduce that
slowly during the first operating hours by
continuously fastening of gland (see position "69"
and "M2" in sectional drawing) when pump is
running. Assume 30-100 drops / minute as
approx. value.
shaft sealing resp. the shaft.
atypical sounds or vibrations do occur:
causes (see chapter 10).
6.3 Restarting
Basically, the same procedure should be followed as
for starting up for the first time. However, there is no
need to check the direction of rotation and the
accessibility of the pump unit.
The pump should only be automatically restarted if it
has been made sure that the pump has remained
filled whilst stand by.
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
Be particularly careful not to touch hot machine
parts and when working in the unprotected shaft
seal area. Remember that automatically
trolled systems may switch themselves on
Suitable warning signs
The operating limits of the pump / unit regarding
pressure, temperature, performance and speed
are shown in the data sheet and / or order
ny
On pumping liquids with abrasive components
ling
tion
should be reduced compared to the usual
The bearing bracket must be filled up with oil.
Remove oil filling plug (FS) and fill oil into
Fill in oil up to the middle of the oil level
ep level
exactly. Overfilling leads to increased
bearing temperature and possibly oil
ge. If oil level is too low this can
con
suddenly at any time.
should be affixed.
6.4 Limits of Operation
Model LS, LC, LCP
6.5 Lubrication of Bearings
6.5.1 Oil lubrication
For quality of oil refer to chapter 7.4.1.
For quantity of oil refer to chapter 7.4.1.
The pumps are delivered without oil filling!
Oil level sight glass (standard design)
the connection opening.
confirmation and must be observed under a
circumstances!
Do not exceed the output given on the motor
name plate.
Avoid sudden changes in temperature
(temperature shocks).
The pump and motor should run evenly and
without vibrations; check at least once a week.
6.4.1 Flow min. / max.
If no other data are given in the curves or data sheets,
the following is valid:
Q
= 0,1 x Q
min
Q
= 0,3 x Q
min
Q
= 1,2 x Q
max
Q
= Flow in efficiency optimum
BEP
*) on condition that NPSH
for for short time operation
BEP
for continuous operation
BEP
for continuous operation *)
BEP
facility
> (NPSH
pump
+ 0,5 m)
6.4.2 Abrasive Media
an increased wear at hydraulic and shaft sea
must be expected. The intervals of inspec
times.
6.4.3 Permitted number of starts
The permitted number of starts of the pump must not
be exceeded, see diagram 6.
100,0
sight glass (ÖA) (pic 7). Ke
pic 7
leaka
cause shortcoming of lubrication.
Constant level oiler (special design)
Supplied loose.
Unscrew the reservoir from the main body (right
threaded) and set aside.
Seal the main body into the bearing bracket (10),
through a PTFE sealing tape, at connection for
constant level oiler (ÖK). Tighten until threaded
boss is in vertical position (picture 8).
Remove the oil filling plug (FS) (upper side of
bearing bracket) and fill in oil through the
connection opening (GF1), until the oil level
reaches almost the middle of the oil level sight
glass in the main body.
Using a funnel, fill the reservoir (picture 8).
Make sure that o-ring is on reservoir spout.
Place thumb over reservoir spout, invert, and
insert the spout into the internal threaded boss on
the main body. Tighten reservoir (picture 8).
Now the oil is flowing from the reservoir into the
bearing chamber.
Repeat filling till the reservoir stays full to 2/3rd.
Refill oil as soon as the oil level falls below 1/3rd.
10,0
max. perm. starts/h
1,0
1 10 100 1000
Motor power [kW]
Diagram 6
With electric motors, the permitted number of starts is
given in the attached motor operating instructions.
If two different figures are given, the lower figure is
valid.
LS 100-english page 14
Artikel No. 771073402
10
pic 8
6.5.2 Grease lubrication
For quality of grease refer to chapter 7.4.2.
For quantity of grease refer to chapter 7.4.2.
The bearings are already filled with lithium based
grease at the factory and are thus ready for use.
The grease provided is suitable for a temperature
range from -30° to +90°C (measured at surface of
bearing bracket).
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Revision 02
Installation, Operating and Maintenance Instruction
In areas endangered to explosion it is
mended to monitor the temperature of the
ings and the vibrations of the bearing
tend
After long stationary periods, packing may have
starting up, follow the instructions for
Work should only be carried out on the pump or
You must
servicing work must only be
carried out by trained, experienced staff who
are familiar with the contents of these Operating
Instructions, or by the Manufacturer's own
Re-lubrication via the two grease nipples (SN).
6.5.3 Bearing temperature
Bearing temperature (measured at bearing
bracket) should lie max. 50°C over ambient
temperature and must not exceed 90°C, control
weekly at least. On grease lubrication the bearing
temperature can temporarily be higher by 5-10°C
after regreasing, till a possible surplus of grease in
the bearings is cut.
6.6 Monitoring
recom
bear
bracket.
Regular monitoring and maintenance will ex
the life of your pump or pump system.
Check oil level at least once a week and top up if
necessary.
Check pump for leaks at least once a week.
On packing, check quantity of leakage at least
once a week (see chapter 6.2 section "Packing").
Check the regulating and monitoring devices of
any sealing, flushing or cooling systems once a
week to ensure that they function properly.
Outgoing cooling water should be hand warm.
With double mechanical seals, monitor pressure
and flow rate in mechanical seal area; check at
least once a week.
Pumps which are exposed to corrosive chemicals
or to wear through abrasion must be inspected
periodically for corrosion or wear and tear. The
first inspection should be carried out after six
months. All further inspection intervals should be
determined on the basis of the state of the pump.
6.7 Shutting down
Close the valve in discharge pipe right before
(max. 30 seconds) switching off the motor. This is
not necessary if there is a spring-loaded check
valve.
Switch off motor (make sure it runs down quietly).
Close the valve on suction side.
Close auxiliary systems. Do not shut down cooling
system until pump has cooled down.
If there is any risk of freezing, empty pump,
cooling areas and pipes completely.
Model LS, LC, LCP
If the pump also remains under operating
conditions (pressure and temperature) when
stationary, leave all sealing, flushing and cooling
systems switched on.
The shaft sealing must remain sealed if there is a
risk of air being sucked in (in the event of supply
from vacuum systems or parallel operation with
shared suction pipe).
6.8 Storage / longer periods of nonoperation
6.8.1 Storage of new pumps
If the putting into operation shall happen a longer
period after the delivery, we recommend the following
measures for the storage of the pump:
Store pump at a dry place.
Rotate pump by hand at least once a month.
6.8.2 Measures for longer putting out of operation
Pump remains installed and in ready for operation:
Test runs of 5 min. duration must be made in
regular intervals. The span between the test runs
is depending on the plant. However, it should be
made once a week, at least.
6.8.3 Longer periods of non-operation
hardened; these must be replaced before startup.
When
starting up for the first time (see chapter 6)!
a) Filled pumps
Switch stand-by pumps on and immediately off
again once a week. Possibly use as main pump.
If the stand-by pump is at operating pressure and
temperature, leave all sealing, flushing and
cooling systems switched on.
Replace oil or grease after 2 years.
Stuffing box must be adjusted to maintain
lubrication of the packing (e.g. do not over
tighten).
b) Drained pumps
Turn shaft at least 1x week (do not switch on
because of dry running).
Replace oil or grease after 2 years.
7. Servicing, Maintenance
7.1 General remarks
pump unit when it is not in operation.
observe chapter 2.
LS 100-english page 15
Artikel No. 771073402
Maintenance and
service staff.
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
t you
Because of the risk of accidents, addition of
packing to pumps during operation or at
ing pressure or temperature is strictly
to explosion the oil
change intervals must be kept under any
Old oil must be disposed of in accordance with
3
3
If wear is heavy, it must be assumed that the
properly aligned with the pump or
that the distance between the coupling sections
install or adjust coupling, as described in
7.2 Mechanical seals
Before opening the pump, it is essential tha
note chapter 2 and chapter 8.
If the liquid being handled leaks out at the mechanical
seal, it is damaged and must be replaced.
Replacement of the mech. seal according to
accompanying "Mounting Instructions for Shaft
sealing".
7.3 Stuffing boxes
Stuffing boxes require constant maintenance, see
chapter 6.2 section "Stuffing box". If the leakage rate
can no longer be set correctly, the packing is worn out
and must be replaced in good time (increased wear on
shaft sleeve). Replacement of stuffing boxes acc. to
attached "Mounting Instructions for Shaft Sealing".
operat
forbidden!
7.4 Lubrication and Change of Lubricant
7.4.1 Oil lubrication
Temperature at
bearing
First oil change
after .....
operating hours
All further oil
changes
after .....
operating hours
bis 60°C 300 8760 *)
60°C - 80°C 300 4000 *)
80°C - 90°C 200 3000 *)
*) at least 1x year
In plants endangered
circumstances!
Oil change
After the first ....... operating hours, drain oil (oil
drain "AS" with drain plug and flush with fresh oil.
Clean oil drain plug and close oil drain again.
Fill in new oil according to chapter 6.5.
If the pump is left idle for a longer time, the oil
should be changed after two years.
the valid national environmental regulations.
Oil quality
Lubricating oil
Name
Symbol acc. DIN 51502
Cinematic viscosity at 40°C
Flash point (acc. to Cleveland)
Setting point (Pour point)
Application temperature *)
LS 100-english page 16
Artikel No. 771073402
CLP46
DIN 51517 or
HD 20W/20 SAE
46 ±4 mm2/s
+175°C
-15°C
higher than
permitted bearing
temperature
Model LS, LC, LCP
*) For ambient temperatures under -10°C another suitable type of
lubrication oil must be used.
Request required.
Oil quantity
Bearing bracket Oil quantity in l
42 S 1,9
55 S 3,7
75 S, 90 S 7,5
100 S 18,0
7.4.2 Grease lubrication
Re-greasing
Grease lubricated bearings with the possibility of
re-greasing must be re-lubricated all 4000
operating hours, but at least 1x year. Clean
lubricating nipples (SN) first.
Quality of grease lubricant ...
... corresponding to NLGI GRADE 2
Quantity of re-greasing (approx. value)
Bearing bracket
bearing at pump
side
42 S 20 g / 22 cm3 35 g / 39 cm3
55 S 30 g / 33 cm3 60 g / 66 cm3
75 S, 90 S 50 g / 55 cm3 100 g / 110 cm
100 S 75 g / 83 cm3 145 g / 160 cm
If the pump is left non-operational for a longer
time, the grease in the bearings should be
changed after 2 years.
7.5 Coupling
Check the clearance in the coupling components
regularly approx. every 1000 operating hours, but at
least 1x year, the radial clearance in the coupling parts
must be checked.
For couplings with rubber pads the following applies:
Unless a clearance in the couplings is necessary, the
coupling pads may wear out to approximately ¼ of
their usual thickness, before they have to be changed.
For the measurement of the clearance in the coupling
place a mark on the O.D. of each coupling hub (see
following pic). Then fix one hub, turn the opposite hub
as far as possible. Then measure the distance (∆SV)
between the marks of the coupling. If this measure
exceeds the value given in the chart, the packing must
be replaced. It must be replaced in sets.
Size 80 95 110 125 140 160 180 200 225 250 280 315 350 400
∆Sv [mm]
5,0 6,0 7,0 8,0 8,5 8,0 8,0 8,5 9,0 10,0 11,5 10,5 11,5 13,0
motor is not
has changed. Replace worn elements and re-
chapter 5.3.
bearing at drive
side
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
ised
water
Repair to the pump or pump system may only
be carried out by authorised skilled personnel or
If dangerous liquids are pumped the appropriate
disposal of the handled liquid is necessary
fore the disassembly of the pump. Pay
attention to the fact, that even in drained pumps
rs of the handled liquid. If
necessary the pump must be flushed or
decontaminated. Laws must be observed,
Secure disassembled pumps, units or single
While disassembling the pump use of an open
flame (blowlamp, etc.) only, when there is no
danger of setting fire, cause an explosion or
Never apply heat to remove the impeller nut.
l injury
Use original spare parts only. Pay attention to
Works, which require shocks (hammer), must
only be performed outside the explosive
ng tools must be
7.6 Cleaning of pump
The pump must not be cleaned with pressur
- water will get into the bearings.
Dirt on the outside of the pump has an adverse
effect on transmission of heat. The pump should
8. Dismantling and repair of pump
Model LS, LC, LCP
therefore be cleaned with water at regular
intervals (depending on the degree of dirt).
Radial-Shaft sealing (WD1 and WD2) are not
completely free from leakage. Impurities could
cause leakage at the shaft sealing area of the
frame. Therefore wipe off impurities with a rag
from time to time.
Replace dirty oil level sight glass (ÖA).
8.1 General remarks
by the manufacturer’s specialist staff.
When disassembling the pump pay attention to
chapter 2 and chapter 4.1.
For mounting and repair you can order specialized
personnel if you want.
be
there are remainde
otherwise danger to health is existing!
Before the disassembly the pump has to be
secured in such a way, that it can’t be started.
The pump casing must be drained and without
pressure.
All locking devices in the suction- and discharge-
pipe must be closed.
All parts must have taken on the temperature of
the environment.
Before disassembly check if required parts are ready.
Disassemble the pump only so far, as required for the
replacement of the repair part.
8.3 Disassembly of Back Pull Out
Assembly
The Back Pull Out Assembly includes all parts of the
pump except the volute casing (4). As the pumps are
constructed for process design the volute casing (4)
can stay on the base frame and in the pipes, unless
the volute casing itself must be repaired.
Drain volute casing (4) through the drain plug (E).
Unscrew all auxiliary piping (flush, cooling,
quench, a.s.o.) and drain lubrication oil from
bearing bracket (10) via the screwed oil plug (AS).
Remove coupling guard.
Remove spacer of the spacer type coupling (if
available). Remove motor at standard coupling.
Loosen screws for support foot (80/F) from the
base frame.
Hang the Back Pull Out Assembly onto a lifting
device, so that it won’t sink down or press into the
volute casing during the dismounting. Example
see picture 9 for lifting recommendations.
parts against tipping over or rolling off.
cause injurious vapours.
Use of heat may result in severe physica
and property damage.
the right materials and the matching design.
8.2 General
atmosphere or only non-sparki
used.
Carry out disassembly and mounting according to the
appropriate sectional drawing.
You will only need common tools.
LS 100-english page 17
Artikel No. 771073402
pic 9
Loosen casing screws (hexagon nuts "M1").
Using the possibly available jack screws, separate
the Back Pull Out Assembly from the casing.
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
Note attached "Mounting Instruction for Shaft
Be sure to locate pry bars under impeller vanes
All sealing materials of PTFE resp. Graphite are
8.4 Removal of Impeller
Model LS, LC, LCP
Sealing".
Loosen impeller nut (28) (right threaded) by fixing
the rotor at the coupling end.
Draw off the impeller (1) with two screw drivers or
pry bars (picture 10). Remove key (PF1).
pic 10
to prevent damage to the impeller.
For further dismounting the Back Pull Out
Assembly should be placed in the vertical position
(with vertical shaft, see picture 11). Attention:
Precautions should be taken to prevent the Back
Pull Out Assembly from tipping!
pic 11
8.5 Removal of Shaft Sealing
Before you remove the casing cover (18..) notice
"Mounting Instructions for Shaft Sealing".
8.6 Removal of Bearing
Remove coupling with a coupling puller (picture
12), remove coupling key (PF2).
LS 100-english page 18
Artikel No. 771073402
pic 12
Remove the flinger (73).
Loosen and remove hexagon screws (S5) resp.
hexagon nuts (M5), remove the lantern (11).
Only for bearing bracket 100S: Unscrew the
hexagon nuts (M8) and demount the bearing
cover (12/P).
Loosen and remove the hexagon screws (S6),
remove the bearing cover (12).
Move the shaft (24) with the pair of angular
contact bearings (K2) and the inner ring of the
roller bearing (K1) with haps by a wood or plastic
hammer with caution to the drive end (picture 13).
picture 13
Demount the roller bearing (K1) (cage) off the
bearing bracket (10).
Bend up the lock washer (SB), unscrew the
bearing nut (50) (right threaded), remove the lock
washer (SB).
Heat up the angular contact bearings (K2) and the
inner ring of the roller bearing (K1) and remove it
with qualified tools (e.g. with hook proof-puller)
from the shaft (24).
8.7 Reconditioning
After disassembly all parts must be cleaned and
checked for wear carefully. Worn or damaged parts
must be replaced by new parts (spare parts).
When reassembling the pump it is recommended to
replace all seals (flat gaskets, o-rings and radial shaft
seal rings).
intended for being used only once.
In most cases it make sense, if damaged absolutely
necessary, to renew the mechanical seal and the
bearings.
Deposits on the impeller (1), on the volute casing (4)
or on the casing cover (18) must be removed.
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
When the wear limits has been reached or
galling compound must be compatible with
It is only allowed to mount a pair of angular
The angular contact bearings (K2) must be
8.7.1 Clearance at impeller
Suction side of impeller Drive side of impeller
Pump
size
125-330 200
125-500 220
150-500 250
200-260 220
200-350 250
200-400 270
200-500 250
250-315 250
250-350 270
250-400 280
250-500 280
300-400 315
300-450 315
300-500 330
350-450 380
400-400 370
600-600 515
Values in parenthesis are valid for code VV and WW.
*) nominal diameter
exceeded, the worn parts must be replaced.
Suction side Drive side
Radial clearance
D *)
(mm)
s (mm) D *)
new wear
0,20
0,24
(0,45)
(0,50)
0,20
0,24
(0,45)
(0,50)
0,20
0,24
(0,45)
(0,50)
0,23
0,28
(0,50)
(0,55)
0,23
0,28
(0,75)
(0,80)
0,28
0,23
(0,65)
(0,60)
0,23
0,28
(0,50)
(0,55)
0,23
0,28
(0,75)
(0,80)
0,23
0,28
(0,60)
(0,65)
0,23
0,28
(0,75)
(0,80)
0,23
0,28
(0,70)
(0,75)
0,23
0,28
(0,68)
(0,73)
0,23
0,28
(0,68)
(0,73)
0,23
0,28
(1,00)
(1,05)
0,25
0,29
(0,68)
(0,73)
0,25
0,29
(0,65)
(0,75)
0,25
0,30
(0,65)
(0,75)
limit
1,15
(1,40)
1,15
(1,40)
1,20
(1,45)
1,15
(1,45)
1,20
(1,75)
1,25
(1,65)
1,20
(1,50)
1,20
(1,75)
1,25
(1,65)
1,25
(1,80)
1,25
(1,75)
1,33
(1,80)
1,33
(1,80)
1,40
(2,20)
1,45
(1,90)
1,45
(1,90)
1,60
(2,05)
(mm)
200
250
250
220
250
270
250
250
270
280
280
315
315
330
350
250
515
Radial clearance
s (mm)
new wear
min. max.
0,20
0,24
(0,45)
(0,50)
0,20
0,24
(0,50)
(0,55)
0,20
0,24
(0,50)
(0,55)
0,23
0,28
(0,50)
(0,55)
0,23
0,28
(0,75)
(0,80)
0,28
0,23
(0,65)
(0,60)
0,23
0,28
(0,50)
(0,55)
0,23
0,28
(0,75)
(0,80)
0,23
0,28
(0,60)
(0,65)
0,23
0,28
(0,75)
(0,80)
0,23
0,28
(0,70)
(0,75)
0,23
0,28
(0,68)
(0,73)
0,23
0,28
(0,68)
(0,73)
0,23
0,28
(0,70)
(0,75)
0,25
0,29
(0,68)
(0,73)
0,20
0,24
(0,45)
(0,50)
0,25
0,30
(0,65)
(0,75)
limit min. max.
1,15
(1,40)
1,20
(1,50)
1,20
(1,50)
1,15
(1,45)
1,20
(1,75)
1,25
(1,65)
1,20
(1,50)
1,20
(1,75)
1,25
(1,65)
1,25
(1,80)
1,25
(1,75)
1,33
(1,80)
1,33
(1,80)
1,40
(1,90)
1,45
(1,90)
1,45
(1,70)
1,60
(2,05)
There are the following possibilities to restore the
correct clearances:
a) Renew impeller(1) and wear rings (9/S und 9/D).
Then the original measures are restored.
b) A customized wear ring (bored to fit) can be
supplied to avoid replacement of the impeller.
Please contact factory for details.
8.8 Mounting
Re-assemble the pumps using the reverse order of
steps as completed for pump disassembly. However
the following observations should be considered:
Pay attention to the utmost cleanliness when
reassembling the pump.
LS 100-english page 19
Artikel No. 771073402
Model LS, LC, LCP
For tight tolerances, e.g. between shaft sleeve
(44) and shaft (24) or impeller (1) and shaft (24),
as well as thread, use a suitable anti-galling
compound (e.g. Molykote/Never-Seeze), so that
the assembly and the next disassembly will be
easier.
Antithe pumpage.
Screws should be tightened, with the following
torque:
Location
Casing screws
All other screws
Values in parenthesis are valid for:
- size M20 for pump size LS 400-400 and model LC & LCP
- size M24 for pump size LS 608-600 and LS 606-600
It is only allowed to use the prescribed bearings
according chapter 3.3.1.
bearings from one manufacturer.
Heat the angular contact bearings (K2) and the
inner ring of the roller bearing (K1) in an oil bath or
inductive up to 80 C, slide the bearings until the
contact surface on the shaft (24) and press it as
long as it fits tightly on the shaft.
mounted in X-arrangement resp. in Oarrangement at bearing bracket 100S.
Don the lock washer (SB) and fasten the bearing
nut (50) with a hook wrench.
Cool down to ambient temperature the angular
contact bearings.
Refasten the bearing nut (50) and bend the lock
washer (SB) of the bearing nut.
Pay attention at the mounting of the shaft (24),
with assembled angular contact bearings (K2) and
inner ring of the roller bearing (K1) into the bearing
bracket (10) that the running surface of the roller
bearing does not get damaged by the edges of the
rolls.
At the assemble pay attention of the bearing
bracket (10) with the lantern (11) and from the
lantern (11) with the volute casing (4) that the
screws are positioned in the centre of the
clearance holes.
Otherwise the bearing bracket (10) tilts against the
volute casing (4) and then exact adjustment of the
oil level is affected.
For mounting of the shaft sealing (packing or
mechanical sealing) see separate description
"Mounting Instruction of Shaft Sealing" and
chapter 8.5.
Screw
Size
M16 75 110
M20 165 (255) 255 (385)
M24 325 (440) 495 (665)
M30 575 870
M12 40 60
M16 100 150
M20 190 290
M24 330 500
Screw torque in Nm
Lubricated
thread
Dry thread
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
Before starting the pump do not forget to fill in
Before starting the pump do not forget to install
Joints for pump casing
To ensure optimum availability, we recommend
that suitable quantities of spare parts are held in
m special
materials and in the case of mechanical seals,
re
e or
cause damage to property or high costs.
lar checks should be carried out to ensure
that such pumps are always ready for use (see
Model LS, LC, LCP
After the mounting of the back pull out assembly,
and its assembly into the volute casing, turn the
shaft and control the free moving of the pump in
spacer coupling, if pump casing and motor were
not disassembled.
this way. The shaft sealing will cause slightly
resistance when turning, but there must not be
any contact between metal parts.
Before starting the pump check alignment of the
coupling. This can be dropped on pumps with
9. Recommended Spare Parts, Spare Pumps
oil!
and connect all security devices.
9.1 Spare Parts
Spare parts should be selected to last for two-year
continuous operation. If no other guidelines are
applicable, we recommend that you stock the number
of parts listed below (in accordance with DIN 24296).
Number of pumps
Spare Parts Number of Spare Parts
Impeller 1 1 1 2 2 2 20%
Wear ring 2 2 2 3 3 4 50%
Shaft with key and nuts 1 1 1 2 2 2 20%
Ball Bearing set 1 1 2 2 2 3 25%
Shaft sleeve 2 2 2 3 3 4 50%
Lantern ring 1 1 2 2 2 3 30%
Packing ring 16 16 24 24 24 32 100%
sets
other joints sets 4 6 8 8 9 10 100%
Mech. Seals
Bearing (lantern with
bearing bracket,
complete with shaft,
bearings, aso.)
2 3 4 5 6/7 8/9 10/+
4 6 8 8 9 12 150%
set 1 1 2 2 2 3 25%
(incl. stand-by pumps)
- - - - - - 2
stock, especially if these are made fro
because of the longer delivery times.
10. Faults - Causes and Solutions
Spare Parts Order
When ordering spare parts, please supply the
following information:
Type:
S/N (Order No.):
Part name:
Sectional Drawing
______________________________________________________________________
___________________________________________________
_
_____________________________________________________________
__________________________________________________
All the information is given in the data sheet and the
relevant sectional drawing.
Store spare parts in dry and clean rooms!
9.2 Stand-by pumps
It is essential that a sufficient number of standby pumps are kept ready for use in plants whe
failure of a pump could endanger human lif
Regu
chapter 6.8).
Store stand-by pumps according to chapter 6.8.
The following notes on causes of faults and how to
repair them are intended as an aid to recognising the
problem. The manufacturer's Customer Service
Department is available to help repair faults that the
operator cannot or does not want to repair. If the
operator repairs or changes the pump, the design data
on the Data Sheet and chapter 2 of these Operating
Instructions should be particularly taken into account.
If necessary, the written agreement of the
manufacturer must be obtained.
LS 100-english page 20
Artikel No. 771073402
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
compare speed of motor with specified pump speed (rating
adjust in line with the system pressure/intake pressure given on
Model LS, LC, LCP
Discharge too low
Discharge stops after a time
Head too low
Head too high
Drive mechanism overloaded
Pump not running quietly
Temperature in pump too high
Back-pressure too high
Speed too high reduce speed
Speed too low increase speed (check available motor power)
Impeller diameter too big use smaller impeller
Impeller diameter too small use larger impeller (check available motor power)
Pump or suction/intake pipe blocked clean
Air pocket in pipeline vent
Air being sucked in increase liquid level
Air being sucked in through shaft sealing clean sealing pipe
Direction of rotation is wrong swap over two phases of power supply (to be done by an
Density and/or viscosity of liquid handled is too high seek assistance
Electricity supply not right (2-phase running) check voltage of all phases
Temperature in shaft sealing too high
Flow too little increase min. flow (open discharge valve, bypass)
Pump and/or pipes not completely filled with liquid fill
Suction height too big / NPSH of system too small
System-related vibrations (resonance) seek assistance
Stuffing box is fastened too tight resp. shaft sealing is worn loosen stuffing box
Cause
Temperature at the bearing too high
Pump leaking
Leakage rate at shaft sealing too high
Back-pressure too low, discharge too low throttle discharge valve
Flow too big reduce flow (throttle discharge valve)
Inner components suffering from wear replace worn parts
Stuffing box not straight tighten evenly
Lines and roughness on shaft or shaft sleeve replace parts
Unsuitable packing material use suitable material (check shaft or shaft sleeve for damage
Deposits on mechanical seal
Impeller out of balance
Coupling not aligned align pump unit better
Coupling distance too small change
Forces in pipeline too high (pump unit under strain) change (support pipes, use compensators, etc.)
Too much, too little or the wrong type of lubricant change
Sealing insufficient tighten screws
Bearing damaged replace
Relief fittings insufficient
Solution
check facility for pollution, open discharge valve
reduce resistance in discharge pipe (e.g. clean filter if
necessary)
use larger impeller (note available motor power)
compare speed of motor with specified pump speed (rating
plate)
when adjusting speed (frequency transformer) check reference
value setting
plate)
when adjusting speed (frequency transformer) check reference
value settings
vent
improve course of pipe
increase liquid level and admission pressure
reduce resistance in the intake/suction pipe (change course
and rated width, open shut-off valves, clean filters)
check if suction pipe is vacuum-tight
increase sealing pressure
replace shaft sealing
electrician)
replace packing and/or mechanical seal
check sealing, flushing and cooling pipes (pressure)
avoid dry running
beforehand)
clean
replace mechanical seal if necessary
if necessary provide additional rinsing or quench
remove blocks/deposits
replace impeller if broken or unevenly worn
check shafts to ensure that they are running true
is foundation plate/frame properly cast in place?
check cable connections and fuses
replace sealing
check lubricant and bearing space for pollutants (rinse oil area)
clean relief openings in impeller
replace worn parts (impeller, split rings)
ordering
LS 100-english page 21
Artikel No. 771073402
Issue 01/2010
Revision 02
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