Allweiler AEB.E Series User manual

Progressive Cavity Pump
Operating instructions Series:
AE(B).E, AE(B).F, AE(B).H,
AE(B).L, AE(B).N, AE.V,
AED(B).E, AED(B).N
Designs:
DE,ID,IE,RG,ZD,ZE
Version BA-2020.05 en-US
176-982/0
ID-No. 260371
ALLWEILER GmbH
Postfach 200123
Kirchhellener Ring 77-79
46244 Bottrop
Germany
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: http://www.allweiler.com
We reserve the right to make technical changes.
Read carefully before use.
Retain for future use.

Table of contents
Table of contents
1 About this document ............................... 5
1.1 Target groups ................................. 5
1.2 Other applicable documents ................ 5
1.3 Warnings and symbols ....................... 6
2 Safety ................................................. 7
2.1 Intended use .................................. 7
2.2 General safety instructions .................. 7
2.2.1 Product safety ................................ 7
2.2.2 Operator’s obligations ....................... 7
2.2.3 Obligations of personnel ..................... 8
2.3 Specific hazards .............................. 8
2.3.1 Explosion-hazard area ....................... 8
2.3.2 Hazardous pumped liquids .................. 8
3 Layout and function ................................ 9
3.1 Labels ......................................... 9
3.1.1 Nameplate .................................... 9
3.1.2 Pump type code .............................. 9
3.2 Layout ......................................... 10
3.2.1 Base version .................................. 10
3.2.2 RG version (open-feed version with internal
gearbox mounting) ........................... 11
3.3 Function ....................................... 11
3.4 Shaft seals .................................... 11
3.4.1 Packing gland ................................ 11
3.4.2 Mechanical seals ............................. 11
3.5 Bearings and lubrication ..................... 11
3.6 Auxiliary systems .. ... ... ... ... .. . .. . .. ... ... . 12
3.6.1 Sealing system ... .. . .. ... ... ... ... ..... ... ... 12
3.6.2 Heating and cooling system (optional) ... .. 12
3.7 Types of setup ................................ 12
4 Transport, storage and disposal .................. 13
4.1 Transport ...................................... 13
4.1.1 Unpacking and inspection on delivery . ... .. 13
4.1.2 Lifting .......................................... 13
4.2 Treatment for storage ........................ 13
4.3 Storage ....................................... 14
4.4 Removing preservative ...................... 14
4.5 Disposal ....................................... 14
5 Setup and connection .............................. 15
5.1 Preparing the setup .......................... 15
5.1.1 Determining the setup type .................. 15
5.1.2 Checking the ambient conditions ... ... ... . . 15
5.1.3 Preparing the installation site ............... 15
5.1.4 Preparing the foundation and surface ... . .. 15
5.1.5 Removing preservative ...................... 15
5.1.6 Installing the heat insulation (optional) . ... . 15
5.2 Installation on a foundation .................. 16
5.2.1 Placing the pump unit on the
foundation .................................... 16
5.2.2 Fastening the pump unit ..................... 16
5.3 Installing the motor ........................... 17
5.3.1 Close-coupled pump with stub shaft .. .... .. 17
5.3.2 Pump with coupling .......................... 17
5.3.3 Pump with belt drive ......................... 17
5.4 Planning the pipes ........................... 17
5.4.1 Specifying supports and flange
connections ................................... 17
5.4.2 Specifying nominal diameters ... ... ... ... . .. 18
5.4.3 Specifying pipe lengths ...................... 18
5.4.4 Optimizing changes in cross-section and
direction ...................................... 18
5.4.5 Discharging leaks ............................ 18
5.4.6 Providing safety and control devices
(recommended) .............................. 18
5.5 Connecting the pipes ........................ 19
5.5.1 Keeping the piping clean .................... 19
5.5.2 Installing auxiliary piping ..................... 19
5.5.3 Installing the suction pipe .................... 19
5.5.4 Installing the pressure line ................... 19
5.5.5 Inspection for stress-free pipe
connections ................................... 19
5.5.6 Inspecting the support foot on the discharge
casing (504) for distortion ................... 19
5.6 Electrical connection ......................... 19
5.7 Aligning the coupling precisely .............. 20
5.8 Aligning the motor ............................ 21
5.9 Installing the safety guarding ................ 21
5.9.1 Coupling guard ............................... 21
5.9.2 Belt guard ..................................... 21
6Operation ............................................ 22
6.1 Preparing initial start-up ..................... 22
6.1.1 Identifying the pump type .................... 22
6.1.2 Removing preservative ...................... 22
6.1.3 Preparing auxiliary systems (if
available) ..................................... 22
6.1.4 Filling pump ................................... 22
6.1.5 Turning the pump ............................ 22
6.1.6 Checking the sense of rotation .............. 23
6.2 Start-up ....................................... 23
6.2.1 Switching on .................................. 23
6.2.2 Switching off .................................. 23
6.3 Shutting down the pump ..................... 24
6.3.2 Draining the pump ........................... 24
6.4 Start-up following a shutdown period .. ... .. 24
6.5 Operating the stand-by pump ............... 24
7 Maintenance ......................................... 25
7.1 Inspections ................................... 25
7.2 Maintenance .................................. 25
7.2.1 Antifriction bearings lubricated with
grease ......................................... 26
7.2.3 Spur gear with oil lubrication (RG
design) ........................................ 26
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Table of contents
7.2.4 Joints with oil lubrication ..................... 26
7.2.5 Packing gland ................................ 26
7.2.6 Mechanical seals ............................. 26
7.2.7 Drive seal (RG design) ...................... 26
7.2.8 V-belt drive ................................... 27
7.2.9 Motor .......................................... 27
7.2.10 Cleaning the pump ........................... 27
7.3 Dismounting .................................. 27
7.3.1 Returning the pump to the manufac-
turer ........................................... 28
7.3.2 Dismounting .................................. 28
7.4 Installing ...................................... 29
7.5 Ordering spare parts ......................... 29
8 Troubleshooting .................................... 30
8.1 Pump malfunctions ........................... 30
9 Appendix ............................................. 33
9.1 Sectional drawings ........................... 33
9.1.1 Part numbers and designations ............. 33
9.1.2 Sectional drawings ........................... 39
9.2 Technical specifications ...................... 47
9.2.1 Ambient conditions ........................... 47
9.2.2 Preservatives ................................. 47
9.2.3 Cleaning agents .............................. 47
9.2.4 Parameters for auxiliary systems . .. . .. ..... 47
9.2.5 Lubricants ..................................... 48
9.2.6 Lubrication quantities (RG design) .. . ... ... . 48
9.2.7 Tightening torques ........................... 49
9.2.8 Sound pressure level ........................ 49
9.2.9 Technical data for specificpump
groups ......................................... 52
9.2.10 Total volume and residual liquid
quantity ....................................... 53
9.3 Declaration of harmlessness ................ 56
9.4 Declaration of conformity according to EC
Machine Directive ............................ 57
List of figures
Fig. 1 Nameplate (example with explosion
protection mark) .............................. 9
Fig. 2 Pump type code (example) .................. 9
Fig. 3 Layout – AE, ID design ...................... 10
Fig. 4 Layout – AE, RG design (open-feed version
with internal gearbox mounting) ............. 11
Fig. 5 Horizontal dry pump setup .................. 12
Fig. 6 Horizontal dry pump unit setup .............. 12
Fig. 7 Vertical dry pump unit setup, wall
installation .................................... 12
Fig. 8 Fastening the lifting gear to the pump (as
illustrated) ..................................... 13
Fig. 9 Fastening the lifting gear to the pump unit,
close-coupled pump (as illustrated) . .. . ... .. 13
Fig. 10 Installation with foundation .................. 16
Fig. 11 Straight pipe lengths upstream
and downstream of the pump
(recommended) .............................. 18
Fig. 12 Checking the alignment of the
coupling ....................................... 20
Fig. 13 Checking for lateral and vertical
misalignment ................................. 20
Fig. 14 Checking for angular displacement ... ... ... 20
Fig. 15 Residual liquid in the pump .................. 28
Fig. 16 AE, design ID and AEB, design IE .......... 39
Fig. 17 AE, design ZD and AEB, design ZE . ... .. .. 40
Fig. 18 AE, dosing pump design ..................... 41
Fig. 19 AE, design RG (version with worm on
universal joint shaft) .......................... 42
Fig. 20 AE, design RG (detailed views: mixing screw
and bearings of specific sizes) .............. 43
Fig. 21 Packing gland with flushing ring (P02) . . .. . 44
Fig. 22 Packing gland with internal lantern ring
(P03) .......................................... 44
Fig. 23 Packing gland with external lantern ring
(P04) .......................................... 44
Fig. 24 Mechanical seal, single-action (G0K and
G0N) .......................................... 44
Fig. 25 Mechanical seal, single-action with throttle
ring (G0S and G0T) .......................... 45
Fig. 26 Mechanical seal, single-action with
quenching (G0Q) ............................. 45
Fig. 27 Mechanical seal, double-action (G0D) ... .. 45
Fig. 28 Stator versions ............................... 46
List of tables
Tab. 1 Target groups and their duties . ... ... .... ... 5
Tab. 2 Other applicable documents and their
purpose ....................................... 5
Tab. 3 Warnings and consequences of disregarding
them ........................................... 6
Tab. 4 Symbols and their meaning ................. 6
Tab. 5 Pump type code .............................. 9
Tab.6 Measurestobetakenifthepumpisshut
down .......................................... 24
Tab. 7 Measures depending on the behavior of the
pumped liquid ................................ 24
Tab. 8 Measures for return .......................... 28
Tab. 9 Malfunction/number assignment ... ... ... ... 30
Tab. 10 Pump troubleshooting list .................... 32
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Table of contents
Tab. 11 Designation of components according to part
numbers ...................................... 37
Tab. 12 Additional information in sectional
drawings ...................................... 38
Tab. 13 Ambient conditions ........................... 47
Tab. 14 Type, duration and deadlines for preservation
when storing the pump ...................... 47
Tab. 15 Cleaning agents .............................. 47
Tab. 16 Sealing medium requirements: .............. 47
Tab. 17 Operating parameters for packing
gland .......................................... 47
Tab. 18 Operating parameters for mechanical seal,
single-action with throttle ring ............... 47
Tab. 19 Operating parameters for double-action
mechanical seal .............................. 48
Tab. 20 Operating parameters for mechanical seal
with quenching ............................... 48
Tab. 21 Operating parameters for the cooling and
heating medium .............................. 48
Tab. 22 Lubricants ..................................... 48
Tab. 23 Lubrication quantities for spur gears
(RG) ........................................... 48
Tab. 24 Lubrication quantities for drive seals
(RG) ........................................... 48
Tab. 25 Tightening torques for screws ............... 49
Tab. 26 Sound pressure level for 1-stage
pumps ......................................... 49
Tab. 27 Sound pressure level for 2-stage
pumps ......................................... 50
Tab. 28 Sound pressure level for 3-stage
pumps ......................................... 50
Tab. 29 Sound pressure level for 4-stage
pumps ......................................... 50
Tab. 30 Sound pressure level for 1+1 stage
pumps ......................................... 50
Tab. 31 Sound pressure level 2+2 stage ............ 50
Tab. 32 Sound pressure level for 4+4 stage
pumps ......................................... 51
Tab. 33 Pump groups ................................. 52
Tab. 34 Technical data for packing gland according
by pump group ............................... 52
Tab. 35 Lubrication quantities by pump group .. ... . 53
Tab. 36 Volumetric flow rate of sealing medium by
pump group ................................... 53
Tab. 37 Tot al vo lume and residual liquid quantity
AE1F and AEB1F ... ... ... ... ... ... ... ... ... . 53
Tab. 38 Total volume and residual liquid quantity
AE1L and AEB1L . ... ... ... .. ... ... ... ... .. .. 53
Tab. 39 Total volume and residual liquid quantity
AE1E and AEB1E .. ..... ... .. ... ... .. ... ... .. 53
Tab. 40 Total volume and residual liquid quantity
AED1E ........................................ 53
Tab. 41 Total volume and residual liquid quantity
AE2E and AEB2E ............................ 54
Tab. 42 Total volume and residual liquid quantity
AE1N and AEB1N ............................ 54
Tab. 43 Total volume and residual liquid quantity
AE2N and AEB2N ............................ 54
Tab. 44 Total volume and residual liquid quantity
AEB3N ........................................ 54
Tab. 45 Total volume and residual liquid quantity
AE4N .......................................... 54
Tab. 46 Total volume and residual liquid quantity
AED2N and AEDB2N ........................ 54
Tab. 47 Total volume and residual liquid quantity
AE1+1H ....................................... 55
Tab. 48 Total volume and residual liquid quantity
AE2H .......................................... 55
Tab. 49 Total volume and residual liquid quantity
AE2+2H ....................................... 55
Tab. 50 Total volume and residual liquid quantity
AE4H .......................................... 55
Tab. 51 Total volume and residual liquid quantity
AE2+2V ....................................... 55
Tab. 52 Total volume and residual liquid quantity
AE4+4V ....................................... 55
Tab. 53 Declaration of harmlessness ............... 56
Tab. 54 Declaration of conformity according to EC
Machine Directive ............................ 57
4 AE BA-2020.05 en-US 260371 – 176-982/0

About this document
1 About this document
This manual
• Ispartofthepump
• Applies to the afore-mentioned pump series
• Describes safe and appropriate operation during all oper-
ating phases
1.1 Target groups
Target group Duty
Operating company Keep this manual available at the site of operation of the system,
including for later use.
Ensure that personnel read and follow the instructions in this
manual and the other applicable documents, especially all safety
instructions and warnings.
Observe any additional rules and regulations referring to the
system.
Qualified personnel, fitter Read, observe and follow this manual and the other applicable
documents, especially all safety instructions and warnings.
Tab. 1 Target groups and their duties
1.2 Other applicable documents
Document Purpose
Acceptance test report Tested performance data of the pump
ATEX additional instructions Operation in explosion hazard areas
Order data sheet Technical specifications, conditions of operation
Setup drawing Setup dimensions, connection dimensions etc.
Declaration of conformity Conformity with standards, contents of the declaration of conformity
(→9.4 Declaration of conformity according to EC Machine Directive,
Page 57).
Sectional drawing Sectional drawing, part numbers, component designations
Technical description Technical specifications, operating limits
Supplier documentation Technical documentation for parts supplied by subcontractors
Tab. 2 Other applicable documents and their purpose
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About this document
1.3 Warnings and symbols
Warning Risk level Consequences of disregarding
the warning
DANGER Immediate acute risk Death, serious bodily harm
Potential acute risk Death, serious bodily harm
CAUTION Potentially hazardous situation Minor bodily harm
NOTE Potentially hazardous situation Material damage
Tab. 3 Warnings and consequences of disregarding them
Symbol Meaning
Safety warning sign
Take note of all information highlighted by the safety warning sign
and follow the instructions to avoid injury or death.
Instruction
1. , 2. , … Multiple-step instructions
Precondition
→Cross reference
Information, advice
Tab. 4 Symbols and their meaning
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Safety
2Safety
The manufacturer does not accept any liability for damage
resulting from disregard of the entire documentation.
2.1 Intended use
• Only use the pump for pumping the agreed pumped media
(→order data sheet).
• Adhere to the operating limits.
• Avoid dry running:
– Make sure the pump is only operated with, and never
without, a pumped medium.
• Avoid cavitation:
– Fully open the suction-side armature and do not use it
to adjust the flow rate.
– Open the pressure-side fitting completely.
• Avoid damage to the motor:
– Note the maximum permissible number of times the
motor can be switched on per hour (→manufacturer’s
specifications).
• Consult the manufacturer about any other use.
• Pumps delivered without a motor must be assembled into
apumpunitaccordingtotheprovisionsofECMachine
Directive 2006/42/EC.
Prevention of likely misuse (examples)
• Note the operating limits of the pump with regard to tem-
perature, pressure, viscosity, flow rate and motor speed
(→order data sheet).
The pressures given in the order data sheet only apply for
approximate static pressure. Consult the manufacturer on
dynamically changing pressure.
• Whenmediacontainingsolids,ensurethelimitsforthepro-
portion of solids and the grain size are maintained (→order
data sheet, technical description).
• When using auxiliary systems, ensure there is a continuous
supply of the appropriate operating medium.
• Do not operate the pump while the pressure-side fitting is
closed.
• Only select the setup type according to these operating
instructions. For example, the following are not allowed:
– Hanging base plate pumps in the pipe
– Overhead installation
– Installation in the immediate vicinity of extreme heat or
cold sources
– Installation too close to the wall
2.2 General safety instructions
Observe the following regulations before carrying out any
work.
2.2.1 Product safety
The pump has been constructed according to the latest tech-
nology and recognized technical safety rules. Nevertheless,
operation of the pump can still put the life and health of the
user or third parties at risk or damage the pump or other prop-
erty.
• Only operate the pump if it is in perfect technical condition
and only use it as intended, staying aware of safety and
risks, and in adherence to the instructions in this manual.
• Keep this manual and all other applicable documents com-
plete, legible and accessible to personnel at all times.
• Refrain from any procedures and actions that would pose
a risk to personnel or third parties.
• In the event of any safety-relevant malfunctions, shut down
the pump immediately and have the malfunction corrected
by appropriate personnel.
• In addition to the entire documentation for the product,
comply with statutory or other safety and accident-preven-
tion regulations and the applicable standards and guide-
lines in the country where the pump is operated.
2.2.2 Operator’s obligations
Safety-conscious operation
• Only operate the pump if it is in perfect technical condition
and only use it as intended, staying aware of safety and
risks, and in adherence to the instructions in this manual.
• Ensure that the following safety aspects are observed and
monitored:
– Intended use
– Statutory or other safety and accident-prevention reg-
ulations
– Safety regulations governing the handling of haz-
ardous substances
– Applicable standards and guidelines in the country
where the pump is operated
• Make personal protective equipment available.
Qualified personnel
• Make sure all personnel tasked with work on the pump
have read and understood this manual and all other appli-
cable documents, especially the safety, maintenance and
repair information, before they start any work.
• Organize responsibilities, areas of competence and the
supervision of personnel.
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Safety
• Ensure that all work is carried out by specialist technicians
only:
– Fitting, repair and maintenance work
– Work on the electrical system
• Make sure that trainee personnel only work on the pump
under supervision of specialist technicians.
Safety equipment
• Provide the following safety equipment and verify its func-
tionality:
– For hot, cold and moving parts: on-site safety guards
for the pump
– For possible electrostatic charges: provide the neces-
sary grounding
Warranty
• Obtain the manufacturer’s approval prior to carrying out
any modifications, repairs or alterations during the warranty
period.
• Only use genuine parts or parts that have been approved
by the manufacturer.
Drive system
For pumps delivered without a drive system, comply with the
following requirements for the drive system:
• When using three-phase asynchronous motors, observe
IEC 60034-30-1.
• Power of the drive according to EN ISO 5199 is recom-
mended (EN ISO 5199 also applicable for drives of pro-
gressive cavity pumps).
• When using combustion engines, consult Allweiler.
• For pumps with stub shaft, connect drive system and pump
directly with stub shaft (special drives required)
•Useflexible coupling according to DIN 740-2.
• Use coupling guard with the following requirements:
– Fastening elements must be connected to the pump
unit in undetachable design (cannot get lost).
– Safety distances against the reaching of hazardous
areas according to EN ISO 13857 must be complied
with.
2.2.3 Obligations of personnel
• All directions given on the pump must be followed (and kept
legible), e.g. the arrow indicating the sense of rotation and
the markings for fluid connections.
• Pump, safety guarding and components:
– Do not step on them or use as a climbing aid
– Do not use them to support boards, ramps or beams
– Donotusethemasafixing point for winches or sup-
ports
– Do not use them for storing paper or similar materials
– Do not use hot pump or motor components as a heating
point
– Do not de-ice using gas burners or similar tools
• Do not remove the safety guarding for hot, cold or moving
parts during operation.
• Use personal protective equipment whenever necessary.
• Only carry out work on the pump while it is not running.
• Isolate the motor from its supply voltage and secure it
against being switched back on again when carrying out
any fitting or maintenance work.
• Reinstall the safety equipment on the pump as required by
regulations after any work on the pump.
2.3 Specific hazards
2.3.1 Explosion-hazard area
•(→ATEX additional instructions).
2.3.2 Hazardous pumped liquids
• Follow the safety regulations for handling hazardous sub-
stances when handling hazardous (e.g. hot, flammable,
poisonous or potentially harmful) pumped liquids.
• Use protective equipment when carrying out any work on
the pump.
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Layout and function
3 Layout and function
3.1 Labels
3.1.1 Nameplate
If the pump is not approved for the explosion-hazard area,
the field 1remains empty.
1
2
3
56
4
Fig. 1 Nameplate (example with explosion
protection mark)
1 Explosion protection mark
2 Pump equipment number
3Pumptype
4 Direction of rotation or flow
5 Direction of rotation or flow
6 Year of manufacture
3.1.2 Pump type code
2
3
4
5
AEB 1 N 200 – ZE
6
1
Fig. 2 Pump type code (example)
Posi-
tion
Meaning
1Series
Product
AE Allweiler progressive cavity pump in a
bearing pedestal design
2
AEB Allweiler progressive cavity pump,
close-coupled
3Number of stages
4Mechanics (F, L, E, N, H, V)
5Size
Design
DE Dosing version with external bearings
ID Industrial version with internal bearings
IE Industrial version with external bearings
RG Open-feed version with internal gearbox
mounting
ZD Feeding screw version with internal
bearings
6
ZE Feeding screw version with external
bearings
Tab. 5 Pump type code
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Layout and function
3.2 Layout
Example representation of 2 variants. Further variants are
described in the appendix (→9.1.2 Sectional drawings,
Page 39).
3.2.1 Base version
123
45 67 48910 11 1112 13
Fig. 3 Layout – AE, ID design
1 Pressure side 6 Suction side/suction casing 11 Bearing
2Stator 7Universal joint shaft 12 Bearing pedestal
3Rotor 8 Shaft seal 13 Top sha f t
4Joint 9 Double casing for shaft seal 1)
5Double casing for suction casing 1) 10 Shaft seal ring
1) optional
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Layout and function
3.2.2 RG version (open-feed version with internal
gearbox mounting)
123 4 56 7489 10 11 10 12 13
Fig. 4 Layout – AE, RG design (open-feed version with internal gearbox mounting)
1 Pressure side 6 Suction side/suction casing 11 Spur gears
2Stator 7Universal joint shaft 12 Bearing pedestal
3 Rotor 8 Stub shaft 13 Top shaft
4 Joint 9 Shaft seal
5Plug housing 10 Bearing
3.3 Function
• Self-priming, rotating positive displacement pump
• One, two, four or eight stages
• The rotor rotates in a stationary stator and displaces the
liquid in the direction of the pump outlet
• Transport and dosage of, for example, highly viscous,
abrasive or solids-containing media
3.4 Shaft seals
Shaft seals used (→Shaft seals, Page 44).
Only one of the following shaft seals can be used.
3.4.1 Packing gland
The packing gland must always leak slightly to carry the
frictional heat away.
Packing gland, housing heated or cooled (optional).
3.4.2 Mechanical seals
Mechanical seals have functional leaks.
• Single-action, unbalanced mechanical seal, optionally with
throttle ring
• Single-action mechanical seal with quenching
• Double-action, balanced mechanical seal with external
flushing
3.5 Bearings and lubrication
Close-coupled pump, IE, DE, ZE design:
• Bearing of the stub shaft in the reinforced bearings of the
drive motor
Directly mounted pump, ID, ZD, RG design:
• Angular and groove ball bearings lubricated with grease
and protected from jet water
• Lubrication of the bearings via grease nipples (ID, ZD)
• Oil-lubricated spur gear (RG)
• Special designs possible on request, for example, oil bath
lubrication (ID)
Universal joint shaft:
• Oil-lubricated and liquid-encapsulated pin joints
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Layout and function
3.6 Auxiliary systems
3.6.1 Sealing system
Sealing systems in various designs are available from the
manufacturer upon consultation.
3.6.2 Heating and cooling system (optional)
The following parts can be tempered with an optional heating
and cooling system (ID and IE design):
• Gland packing casing
• Suction casing
•Stator
The heating and cooling systems of the casings are double-
jacket casings, which are permanently supplied with cooling
and heating medium.
3.7 Types of setup
The following types of setup are possible:
– Horizontal, dry
– Vertical dry, wall installation (only permissible if drive
and bearing at top)
Fig. 5 Horizontal dry pump setup
Fig. 6 Horizontal dry pump unit setup
Fig. 7 Vertical dry pump unit setup, wall installation
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Transport, storage and disposal
4 Transport, storage and disposal
4.1 Transport
Weight specifications (→order data sheet).
4.1.1 Unpacking and inspection on delivery
1. Unpack the pump/aggregate on delivery and inspect it for
transport damage.
2. Report any transport damage to the manufacturer immedi-
ately.
3. Dispose of packaging material according to local regula-
tions.
4.1.2 Lifting
DANGER
Death or crushing of limbs caused by falling or overturning
loads!
Use lifting gear appropriate for the total weight to be trans-
ported.
Select the attachment points according to their center of
gravity and weight distribution.
Use at least two hoisting cables.
For vertical transport: Provide a securing rope between the
hook and load eyebolt of the motor.
Never fasten the lifting gear onto the motor eyebolt (unless
used as a safety device against tipping over for units with
ahighcenterofgravity).
Do not stand under suspended loads.
1. Make sure that all connections are sealed with plugs.
2. Fasten lifting gear according to the following illustrations:
– Place lifting straps around the suction casing of the
pump.
– Place lifting straps around the suction casing and
around the motor of the pump unit.
Fig. 8 Fastening the lifting gear to the pump (as illustrated)
Fig. 9 Fastening the lifting gear to the pump unit,
close-coupled pump (as illustrated)
4.2 Treatment for storage
The pump is not treated for storage at the factory in the
standard version.
Treatment is not necessary for non-rusting materials.
Contact the manufacturer for recommendations regarding
preservatives.
NOTE
Material damage due to missing or inappropriate treatment
for storage!
Treat the pump properly, inside and outside, for storage.
Treat seals, stator elastomer, joint sleeves and rotor worm
exclusively with silicone oil.
1. Preservative appropriate for the type and duration of stor-
age (→9.2.2 Preservatives, Page 47).
2. Use the preservative specified by the manufacturer.
3. All bare metal parts should be treated, inside and outside.
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Transport, storage and disposal
4.3 Storage
NOTE
Material damage due to inappropriate storage!
Treat and store the pump properly.
For a longer storage time, dismantle the elastomer stator
and store it in dark filmat-10to25°C.
1. Seal all openings with blind flanges, blind plugs or plastic
covers.
2. Make sure the storage room meets the following condi-
tions:
–Dry
– Frost-free
– Vibration-free
– Dust-free
3. Turn the shaft once a month.
4. Make sure the shaft and bearing change their rotational
position in the process.
4.4 Removing preservative
Only necessary for pumps treated for storage.
NOTE
High water pressure or spray water can damage bearings!
Do not clean bearing areas with a water or steam jet.
NOTE
Damage from using the wrong cleaning agents!
Ensure the cleaning agent does not corrode the joint
sleeves, stator and seals.
1. Flush the pump with the liquid to remove the preservative.
2. If the liquid must not be contaminated, proceed as follows:
– Disassemble the pump.
– Clean all metal parts with approved cleaning agents.
3. Dispose of preservatives cleaning agents in accordance
with local regulations.
4. For storage times in excess of 12 months:
– Replace the elastomer parts made of EP rubber
(EPDM).
– Check all elastomer parts (stator, O-rings, shaft seals)
for proper elasticity and replace them if necessary.
5. If present, check that all pressure relief valves and check
valves can move freely.
4.5 Disposal
Plastic parts can be contaminated by poisonous or radioac-
tive pumped liquids to such an extent that cleaning will be
insufficient.
WARNING
Risk of poisoning and environmental damage by the
pumped liquid or oil!
Use protective equipment when carrying out any work on
the pump.
Prior to the disposal of the pump:
– Collect and dispose of any leaking pumped fluid or oil
in accordance with local regulations.
– Neutralize residues of pumped liquid in the pump.
– Removing preservative (→4.4 Removing preserva-
tive, Page 14).
Remove the plastic parts and elastomers and dispose of
them in accordance with local regulations.
Dispose of the pump in accordance with local regulations.
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Setup and connection
5 Setup and connection
For pumps in explosion-hazard areas (→ATEX additional
instructions).
NOTE
Material damage due to distortion or passage of electrical
current in the bearing!
Do not make any structural modifications to the pump unit
or pump casing.
Do not carry out any welding work on the pump unit or
pump casing.
NOTE
Material damage caused by dirt!
Do not remove the transportation locks until immediately
before installing the pump.
Do not remove any covers or transport and sealing covers
until immediately before connecting the pipes to the pump.
5.1 Preparing the setup
5.1.1 Determining the setup type
NOTE
Damage to the bearings and shaft seal due to incorrect
setup type!
Set up the pump according to the order-based setup type.
Determine correct setup type (→order data sheet).
5.1.2 Checking the ambient conditions
Make sure the required ambient conditions are fulfilled
(→9.2.1 Ambient conditions, Page 47).
5.1.3 Preparing the installation site
Ensure the installation site meets the following conditions:
– Pump is freely accessible from all sides
–Sufficient space for the installation/removal of the pipes
and for maintenance and repair work, especially for the
removal and installation of the pump and the motor
– Pump not exposed to external vibrations (damage to
bearings)
– Frost protection
5.1.4 Preparing the foundation and surface
Setup options:
– With concrete foundation
– With steel foundation frame
Make sure the foundation and surface meet the following
conditions:
–Level
– Clean (no oil, dust or other impurities)
– Capable of bearing the weight of the pump unit and all
operating forces
– Ensure the pump is stable and cannot tip over
– Ensure base plate makes contact over entire surface
– With concrete foundation: standard concrete of
strength class B 25
5.1.5 Removing preservative
If the pump is to be put into operation immediately after
setup and connection: Remove the preservative prior to
installation (→4.4 Removing preservative, Page 14).
5.1.6 Installing the heat insulation (optional)
Only necessary to maintain the temperature of the pumped
liquid.
NOTE
Material damage on the bearing or shaft seal due to over-
heating!
Install heat insulation only on the pump casing.
Install the heat insulation properly.
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Setup and connection
5.2 Installation on a foundation
NOTE
Material damage due to distortion of the base plate!
Place the base plate on the foundation and secure it as
described in the following.
5.2.1 Placing the pump unit on the foundation
Implements, tools and materials:
– Foundation bolts (→setup drawing)
– Steel washers
– Non-shrinking mortar grout
– Spirit level
1. Lifting the pump unit (→4.1 Transport, Page 13).
2. Attach the foundation bolts from below into the base plate
fixing holes.
Observe the manufacturer’s instructions when using adhe-
sive anchors.
3. Set the pump unit down on the foundation. When doing
so, sink the foundation bolts into the prepared anchoring
holes.
32 1 2
Fig. 10 Installation with foundation
4. Use steel washers to align the pump unit to the height and
system dimensions as described in the following:
– Placeasteelwasher(2)totheleftandright-handside
of each foundation bolt (1).
– If the distance between the anchoring holes is greater
than 750 mm, place additional steel washers (3) in the
middle, on each side of the base plate.
5. Make sure the steel washers lie flat against the base plate,
in full contact.
6. Use the integrated spirit level to check whether the pump is
level end to end and side to side with a maximum allowable
tilt of 1 mm/m.
7. Repeat the procedure until the base plate is correctly
aligned.
5.2.2 Fastening the pump unit
The damping behavior is improved by filling the base plate
with mortar grout. When filling, isolate any present adjust-
ing screw for the engine height adjustment.
1. Fill the anchoring holes with mortar grout.
2. When the mortar grout has set, screw down the base plate
at three points with the specified torque.
3. Before tightening the remaining bolts, compensate for any
unevenness in the surface using metal spacing shims next
to each bolt.
1
4. Check the pump unit for any distortion with a straightedge:
– Measure in two planes at an angle of 90° on the cir-
cumference of the coupling.
– Place the straightedge (1) over both coupling halves
and check the light gap at the outer diameter.
Couplings with spacer piece (spacer coupling) can also be
checked with a dial gauge.
5. If there is significant deviation, undo the fixing to the base
plate and correct the distortion by inserting more shims.
6. Fill the inside of the base plate with concrete, if intended.
Knock on the base plate to ensure that no cavities are cre-
ated in the process.
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Setup and connection
5.3 Installing the motor
Only necessary if the pump unit is assembled on site.
5.3.1 Close-coupled pump with stub shaft
NOTE
Material damage caused by knocks and bumps!
Do not knock or hit any components of the pump.
1. Remove the transport seal for pumps with a mechanical
seal.
2. Clean stub shaft and motor shaft.
3. Push the clamping set onto the stub shaft.
4. Insert the motor shaft into the stub shaft and align both shaft
ends so that they are flush with one another.
5. Align the clamping set correctly.
6. Tighten screws crosswise. Observe the indicated torque
information on the clamping set.
5.3.2 Pump with coupling
NOTE
Material damage caused by knocks and bumps!
Keep the coupling halves properly aligned when slipping
them on.
Do not knock or hit any components of the pump.
1. Lift the motor to the prepared position on the base plate.
2. Smear a very thin coat of molybdenum disulfide (e.g.
Molykote) on the shaft ends of the pump and motor.
3. Insert shaft keys.
4. Without a mounting rig: remove the rubber buffers and heat
thecouplinghalvesuptoapproximately100°C.
5. Slide on the pump-side and motor-side coupling halves
until the shaft ends are flush with the coupling hub. When
doing this, ensure the prescribed spacing between the two
halves of the coupling is maintained (→assembly instruc-
tions for the coupling).
6. Tighten the grub screws on both coupling halves.
7. Use suitable metal shims at the motor to align the end of
the motor shaft to the end of the pump shaft.
8. Screw in the motor bolts, but do not tighten them yet
(→5.8 Aligning the motor, Page 21).
5.3.3 Pump with belt drive
Depending on the version, belt guard or parts thereof
are already attached to the pump unit when the motor is
installed.
Tension rails or pivoting motor base recommended.
NOTE
Damage to the V-belt and the pulleys due to improper
installation!
Install the pulleys on the shafts with the entire hub width
and aligned with each other.
Do not attach and tension the V-belt with a sharp-edged
tool.
For multi-groove V-belts, check for uniform length of all
V-belts.
NOTE
Bearing damage due to high V-belt tension!
Adjust the V-belt tension according to the intended param-
eters (→setup drawing).
1. Lift the motor to the prepared installation site and align it
correctly with the pump.
2. Adjust shaft clearance (→setup drawing).
3. Screw in the motor bolts, but do not tighten them yet.
4. If necessary, install belt guard or parts of it.
5. Push the pulleys onto the shaft ends and align them with
each other.
6. Fasten the pulleys (→manufacturer’s specifications).
7. Put on V-belt.
8. Set correct V-belt tension (→setup drawing).
9. Install the belt guard.
5.4 Planning the pipes
5.4.1 Specifying supports and flange connections
NOTE
Material damage due to excessiveforcesandtorques
exerted by the piping on the pump!
Do not exceed the permissible limits
1. Calculate the pipe forces, taking every possible operating
condition into account:
–Cold/warm
– Empty/full
– Depressurized/pressurized
– Positional changes of the flanges
2. Ensure the pipe supports have permanent low-friction
properties and do not seize up duetocorrosion.
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Setup and connection
5.4.2 Specifying nominal diameters
Keep the flow resistance in the pipes as low as possible.
1. Make sure the nominal suction pipe diameter is ≥as pos-
sible to the nominal suction branch diameter.
– Recommended flowratespeed<1m/s
2. Make sure the nominal pressure pipe diameter is ≥as pos-
sible to the nominal outlet flange diameter.
– Recommended flowratespeed<3m/s
5.4.3 Specifying pipe lengths
A
C
Fig. 11 Straight pipe lengths upstream and downstream
of the pump (recommended)
A > 5 x nominal pressure pipe diameter
B Nominal pressure pipe diameter
C Nominal suction pipe diameter
D > 5 x nominal suction pipe diameter
Maintain the recommended minimum values when
installing the pump.
Suction side: shorter pipes are possible but may restrict
the hydraulic performance.
Pressure side: shorter pipes are possible but can result in
increased operating noise.
5.4.4 Optimizing changes in cross-section and
direction
1. Avoid bending radii of less than 1.5 times the nominal pipe
diameter.
2. Avoid abrupt changes of cross-section along the piping.
5.4.5 Discharging leaks
WARNING
Risk of injury and poisoning due to hazardous pumped
liquids!
Safely collect any leaking pumped liquid, then discharge
and dispose of it in accordance with environmental regula-
tions.
1. Provide equipment for collecting and discharging leaking
liquids.
2. Ensure the free discharge of leaking liquids.
5.4.6 Providing safety and control devices
(recommended)
Avoiding reverse running
Install a non-return valve between the outlet flange and the
stop valve to ensure the medium does not flow back when
thepumpisswitchedoff.
Making provisions for isolating and shutting off pipes
For maintenance and repair work.
Provide shut-off devices in the suction and pressure lines.
Allowing measurement of the operating conditions
1. Provide pressure gauges for pressure measurements in
the suction and pressure lines.
2. Provide for pump-side temperature measurements.
Providing dry-running protection
Provide suitable dry protection to protect the pump against
dry running and resulting damage:
– Select dry protection according to the specific applica-
tion.
– Select dry protection in consultation with the manufac-
turer.
Avoiding high pressures
To switch off the pump at high pressures, provide suitable
shutdown devices, for example, a pressure switch.
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Setup and connection
5.5 Connecting the pipes
5.5.1 Keeping the piping clean
NOTE
Material damage due to impurities in the pump!
Make sure no impurities or foreign particles enter the pump.
1. Clean all piping parts and fittings prior to assembly.
2. Ensure no flange seals protrude inwards.
3. Remove any blank flanges, plugs, protective foils and/or
protective paint from the flanges.
5.5.2 Installing auxiliary piping
Follow the manufacturers’ specifications for any available
auxiliary systems.
Shaft seals used (→Shaft seals, Page 44).
1. Connect the auxiliary pipes to the auxiliary connections so
that they are stress-free and do not leak (→setup drawing).
2. For shaft seals in versions G0Q, G1Q, G0D and G1D:
– Lay auxiliary pipes with a large flow cross-section.
– Connect the sealing media outlet to the highest con-
nection of the sealing housing.
3. To avoid air pockets: run the pipes with a continuous slope
up to the pump. If necessary, install vent connections.
4. For cooling and heating systems for double-jacket casings:
Connect the cooling and heating medium outlet to the high-
est connection on the casing.
5.5.3 Installing the suction pipe
1. Remove the transport and sealing covers from the pump.
2. To avoid air pockets: run the pipes with a continuous slope
up to the pump.
3. Ensure no seals protrude inwards.
4. For suction operation: install a foot valve in the suction pipe
to prevent the pump and suction pipe from runningempty
during downtimes.
5.5.4 Installing the pressure line
1. Remove the transport and sealing covers from the pump.
2. Install the pressure line.
3. Ensure no seals protrude inwards.
5.5.5 Inspection for stress-free pipe connections
Piping installed and cooled down
NOTE
Material damage due to distorted pump casing
Ensure that all pipes are stress relieved when connected
to the pump.
1. Disconnect the pipe connecting flanges from the pump.
2. Check whether the pipes can be moved freely in all direc-
tions within the expected range of expansion:
– Nominal diameter < 150 mm : by hand
– Nominal diameter > 150 mm : with a small lever
3. Make sure the flange surfaces are parallel.
4. Reconnect the pipe connecting flanges to the pump.
5.5.6 Inspecting the support foot on the discharge
casing (504) for distortion
1. Loosen the screwed connection of the support foot on the
discharge casing to the base plate.
2. If the support foot moves or is under pressure, compensate
for distortion by inserting more shims under the base plate.
3. Screw support foot back onto base plate.
5.6 Electrical connection
Follow the instructions of the motor manufacturer.
DANGER
Risk of death due to electric shock!
Have all electrical work carried out by qualified electricians
only.
DANGER
Risk of death due to rotating parts!
Isolate the motor from its supply voltage and keep it locked
when carrying out any fitting or maintenance work.
1. Connect the motor according to the connection diagram.
2. Make sure no danger arises due to electric power.
3. Install an EMERGENCY STOP switch.
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Setup and connection
5.7 Aligning the coupling precisely
Applies to base plate version with coupling
DANGER
Risk of death due to rotating parts!
Isolate the motor from its supply voltage and keep it locked
when carrying out any fitting or maintenance work.
NOTE
Material damage due to incorrect alignment of the cou-
pling!
Align the motor exactly to the pump if there is any vertical,
lateral or angular misalignment.
For detailed information and special couplings: (→manu-
facturer’s specifications).
Checking the alignment of the coupling
Implements, tools and materials:
– Feeler gauge
– Straightedge
– Dial gauge (for couplings with spacer piece)
– Other suitable tools, e.g. laser alignment instrument
1
2
A
Fig. 12 Checking the alignment of the coupling
1. Measure in two planes at an angle of 90° on the circumfer-
ence of the coupling.
2. Check the light gap towards the outer diameter with a
straightedge (1):
– Position the straightedge across both halves of the
coupling.
– Align the motor if there is a visible gap on the outer
diameter (→5.8 Aligning the motor, Page 21).
3. Measure the gap with a feeler gauge (2):
– Permissible gap (→setup drawing)
– Use the feeler gauge to measure the gap (A) between
the coupling halves.
– Align the motor if the gap is too wide (→5.8 Aligning
the motor, Page 21).
Fig. 13 Checking for lateral and vertical misalignment
4. Check for any lateral or vertical misalignment using the dial
gauge:
– Carry out the measurement as illustrated.
– Align the motor if there is any lateral or vertical mis-
alignment (→5.8 Aligning the motor, Page 21).
Permissible axial or radial deviation, measured on the
coupling front or circumference, respectively: ±0.3 mm
Fig. 14 Checking for angular displacement
5. Check the angular displacement with a dial gauge:
– Carry out the measurement as illustrated.
– If there is any angular displacement: align the motor.
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