Allweiler CIRCOR ALLFUEL Series Installation instructions

Screw Pump
Original Operating Manual ALLFUEL Series
Version BA-2021.06 en-US
147-276/H
ID-No. 550 851
ALLWEILER GmbH
Postfach 1140
Allweilerstraße 1
78301 Radolfzell
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 Obligations of the operating company . ..... 7
2.2.3 Obligations of personnel ..................... 8
2.3 Specific hazards .............................. 8
2.3.1 Explosion-hazard area ....................... 8
2.3.2 Electric shock ................................. 8
2.3.3 Hazardous and spraying (pumped)
liquids ......................................... 9
2.3.4 Moving parts .................................. 9
2.3.5 Hot surfaces .................................. 9
3 Layout and function ................................ 10
3.1 Label .......................................... 10
3.1.1 Nameplate .................................... 10
3.1.2 Digital nameplate ............................. 10
3.1.3 ATEX plate .................................... 10
3.1.4 Pump type code .............................. 11
3.2 Layout ......................................... 12
3.3 Shaft seals .................................... 14
3.3.1 Mechanical seals ............................. 14
3.4 Bearings and lubrication ..................... 14
3.5 Auxiliary systems (heating) ... .. . . . . . . . . . . . .. 14
3.6 Hydraulic diagram ............................ 14
4 Transport, storage and disposal .................. 15
4.1 Transport ...................................... 15
4.1.1 Unpacking and inspection on delivery . . . . .. 15
4.1.2 Lifting .......................................... 15
4.2 Treatment for storage ........................ 16
4.2.1 Applying preservative to the inside .. .. . .. .. 16
4.2.2 Applying preservative to the outside .. . . .. . . 16
4.3 Storage ....................................... 16
4.4 Removing the preservative .................. 16
4.5 Disposal ....................................... 16
5 Setup and connection .............................. 17
5.1 Preparing the setup .......................... 17
5.1.1 Checking the ambient conditions . . . . .. . . . .. 17
5.1.2 Preparing the installation site ............... 17
5.1.3 Preparing the surface ........................ 17
5.1.4 Removing the preservative .................. 17
5.1.5 Installing the heat insulation (optional) .. . .. 17
5.2 Setup .......................................... 17
5.2.1 Set up with pump carrier ..................... 17
5.2.2 Setup with base .............................. 17
5.3 Installing the motor ........................... 18
5.3.1 Installing the motor on pumps in flange
versions ....................................... 18
5.4 Planning the pipes ........................... 18
5.4.1 Specifying supports and flange
connections ................................... 18
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 leakage ......................... 18
5.4.6 Avoiding excessive pressure .. .. .. .. . . . . . . . . 19
5.4.7 Providing safety and control devices
(recommended) .............................. 19
5.5 Connecting the pipes ........................ 20
5.5.1 Keeping the pipes clean ..................... 20
5.5.2 Installing the suction pipe .................... 20
5.5.3 Installing the pressure line ................... 20
5.5.4 Checking the stress-free pipe
connections ................................... 20
5.6 Electrical connection ......................... 20
5.6.1 Connecting the motor ........................ 20
5.6.2 Connecting the heater ....................... 20
5.7 Installing the coupling guard ................ 20
6Operation ............................................ 21
6.1 Putting the pump into service for the first
time ............................................ 21
6.1.1 Removing the preservative .................. 21
6.1.2 Preparing auxiliary systems (if
available) ..................................... 21
6.1.3 Filling and bleeding .......................... 21
6.1.4 Checking the sense of rotation .............. 21
6.1.5 Switching on .................................. 22
6.1.6 Switching off .................................. 22
6.2 Operation ..................................... 22
6.2.1 Switching on .................................. 22
6.2.3 Checking the working pressure ............. 22
6.2.4 Switching off .................................. 23
6.3 Shutting down the pump ..................... 23
6.3.2 Draining the pump ........................... 23
6.4 Start-up following a shutdown period ... .. .. 23
6.5 Operating the stand-by pump ............... 23
6.6 Cleaning the filter ............................ 23
7 Maintenance ......................................... 25
7.1 Inspections ................................... 25
7.2 Maintenance .................................. 25
7.2.1 Antifriction bearing ........................... 25
7.2.2 Mechanical seals ............................. 25
7.2.3 Cleaning the pump ........................... 25
7.3 Repairs ........................................ 26
7.3.1 Returning the pump to the manufac-
turer ........................................... 26
7.3.2 Removing the pump from the unit .......... 26
7.3.3 Dismounting .................................. 26
2 ALLFUEL Series BA-2021.06 en-US 550 851 – 147-276/H

Table of contents
7.3.4 Installing ...................................... 27
7.3.5 Adjusting the pressure relief valve .......... 27
7.4 Ordering spare parts ......................... 27
8 Troubleshooting .................................... 28
8.1 Pump malfunctions ........................... 28
8.2 Pressure relief valve malfunctions .. .. . . . .. . 30
9 Appendix ............................................. 31
9.1 Sectional drawings ........................... 31
9.1.1 Auxiliary connections ........................ 31
9.1.2 Part numbers and designations ............. 31
9.1.3 Sectional drawings ........................... 32
9.2 Technical specifications ...................... 37
9.2.1 Ambient conditions ........................... 37
9.2.2 Sound pressure level ........................ 37
9.2.3 Tightening torques ........................... 37
9.2.4 Cleaning agents .............................. 37
9.3 Declaration of harmlessness ................ 38
9.4 Declaration of conformity according to EC
Machine Directive ............................ 39
550 851 – 147-276/H BA-2021.06 en-US ALLFUEL Series 3

Table of contents
List of figures
Fig. 1 Nameplate (example) ........................ 10
Fig. 2 Digital nameplate, standard version
(example) ..................................... 10
Fig. 3 Digital nameplate, variant with optional RFID
transmitter (example) ........................ 10
Fig. 4 ATEX plate (EN 80079-36) .................. 10
Fig. 5 Pump type code (example) .................. 11
Fig. 6 Pump layout .................................. 12
Fig. 7 Layout of twin unit with filter ................. 13
Fig. 8 Circuit diagram of twin unit with filter ....... 14
Fig. 9 Fastening the lifting gear to the pump unit
horizontally (as illustrated) ................... 15
Fig. 10 Fastening the lifting gear to the pump unit
vertically or the filter unit with single pump
(as illustrated) ................................ 15
Fig. 11 Fastening the lifting gear to the twin unit with
filter ............................................ 15
Fig. 12 Straight pipe lengths upstream
and downstream of the pump
(recommended) .............................. 18
Fig. 13 Pump unit ..................................... 32
Fig. 14 Pump .......................................... 33
Fig. 15 Twin unit with filter 1/2 ....................... 34
Fig. 16 Twin unit with filter 2/2 ....................... 35
Fig. 17 Insert unit ..................................... 36
Fig. 18 Pressure gauge .............................. 36
Fig. 19 Changeover ball valve ....................... 36
Fig. 20 Pressure relief valve ......................... 36
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 .............................. 11
Tab. 6 Measures to be taken if the pump is shut
down .......................................... 23
Tab. 7 Measures depending on the behavior of the
pumped liquid ................................ 23
Tab. 8 Measures for returning the pump ........... 26
Tab. 9 Fault number assignment ................... 28
Tab. 10 Pump troubleshooting list .................... 30
Tab. 11 Fault number assignment ................... 30
Tab. 12 Pressure relief valve troubleshooting
list ............................................. 30
Tab. 13 Abbreviations of the connection
designations .................................. 31
Tab. 14 Designation of components according to part
numbers ...................................... 32
Tab. 15 Ambient conditions ........................... 37
Tab. 16 Sound pressure level ........................ 37
Tab. 17 Tightening torques ........................... 37
Tab. 18 Cleaning agents .............................. 37
Tab. 19 Declaration of harmlessness ............... 38
Tab. 20 Declaration of conformity according to EC
Machine Directive ............................ 39
4 ALLFUEL Series BA-2021.06 en-US 550 851 – 147-276/H

About this document
1 About this document
This manual:
• Ispartofthepump
• Applies to the pump series mentioned above
• 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 equipment,
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 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
ATEX additional instructions Operation in explosion-hazard areas
Order data sheet Technical specifications, conditions of operation
Setup drawing Setup dimensions, connection dimensions etc.
Technical description Technical specifications, operating limits
Sectional drawing Sectional drawing, part numbers, component designations
Supplier documentation Technical documentation for parts supplied by subcontractors
Declaration of conformity Conformity with standards, contents of the declaration of conformity
(→9.4 Declaration of conformity according to EC Machine Directive,
Page 39).
Tab. 2 Other applicable documents and their purpose
550 851 – 147-276/H BA-2021.06 en-US ALLFUEL Series 5

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, notes
Tab. 4 Symbols and their meaning
6 ALLFUEL Series BA-2021.06 en-US 550 851 – 147-276/H

Safety
2Safety
The manufacturer does not accept any liability for damages
caused by disregarding the entire documentation.
2.1 Intended use
• Only use the pump to pump the agreed pumped liquids
(→order data sheet).
• Adhere to the operating limits.
• Avoid dry running:
– Make sure the pump is only operated with, and never
without, pumped liquid.
• Avoid cavitation:
– Fully open the suction-side fitting 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 of the pump.
• Pumps delivered without a motor must be assembled into
apumpunitaccordingtotheprovisionsofECMachine
Directive 2006/42/EC.
Prevention of obvious 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.
• 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.
• Pumps may not be used with foodstuffs if they have not
been adapted accordingly. The use of the pump for food-
stuffs must be specified in the order data sheet.
• 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, remaining 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 the personnel responsible.
• 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 Obligations of the operating company
Safety-conscious operation
• Only operate the pump if it is in perfect technical condition
and only use it as intended, remaining 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 protective equipment available.
550 851 – 147-276/H BA-2021.06 en-US ALLFUEL Series 7

Safety
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.
• Make sure that trainee personnel only work on the pump
under the supervision of specialist technicians.
• All activities may only be carried out by specialist personnel
with the required qualifications:
Activities Required personnel
qualifications
Mechanical work
(installation, repairs,
maintenance)
Mechanic
Electro-technical work
(electrical installation)
Qualified electrician
All other work Instruction from operator
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
– If there is no pressure relief valve in the pump: Pro-
vide an appropriate safety valve on the pressure side
between the pump and the first shut-off device
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 screw
pumps).
• When using combustion engines, consult Allweiler.
• For pumps with stub shaft, connect drive system and pump
directly with stub shaft.
•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, coupling guard 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 parts 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.
• If necessary, protective equipment that is appropriate for
the respective assignment must be used:
–Helmet
– Safety shoes
– Safety goggles
– Gloves (min. protection class 3/C)
– Other protective equipment depending on the
(pumped) liquid
• 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 Electric shock
In case of contact with live parts (for example, cables in the ter-
minal box of the electric motor) there is a risk of electric shock
resulting in serious injuries or death.
• Have all electrical work carried out by qualified electricians
only.
8 ALLFUEL Series BA-2021.06 en-US 550 851 – 147-276/H

Safety
2.3.3 Hazardous and spraying (pumped) liquids
(Pumped) liquids can be toxic and hot and can spray out. There
is a risk of burns and skin rashes on contact.
• Follow the safety regulations for handling hazardous sub-
stances when handling hazardous (e.g. hot, flammable,
poisonous or potentially harmful) pumped liquids.
• Before carrying out any work, allow the pump to cool down
properly and then depressurize it.
• Safely collect any leaking (pumped) liquid and dispose of
it in accordance with the environmental rules and require-
ments.
• Drain the pump when carrying out maintenance and repair
work.
• Use protective equipment when carrying out any work on
the pump.
2.3.4 Moving parts
With moving parts (e.g. shaft, coupling) there is a risk of fatal
injuries from being pulled in, crushed or caught.
• Do not touch the pump during operation.
• Do not carry out any work on the pump during operation.
• Keepasufficient distance away from moving parts.
• Isolate the motor from its supply voltage and secure it
against being switched back on again when carrying out
any installation or maintenance work.
2.3.5 Hot surfaces
During operation and after switching off, high temperatures
occur on the housing surfaces. There is a risk of burns when
touching hot surfaces.
• Do not touch the pump during operation.
• Allow the pump to cool down completely before carrying
out any work.
• Wear protective gloves.
550 851 – 147-276/H BA-2021.06 en-US ALLFUEL Series 9

Layout and function
3 Layout and function
3.1 Label
3.1.1 Nameplate
9
Fig. 1 Nameplate (example)
1Pumptype
2 Year of manufacture
3 Discharge pressure
4 Suction head
5 Power consumption
6 Kinematic viscosity
7 Motor speed
8Flowrate
9 Pump number
3.1.2 Digital nameplate
The digital nameplate is an additional plate and contains a
machine-readable pump identification number. The num-
ber is a globally unique identifier for this pump.
A100000000000201
2
1
Fig. 2 Digital nameplate, standard version (example)
1 Identification number
2QRcode
A100000000000201
213
Fig. 3 Digital nameplate, variant with optional RFID
transmitter (example)
1 Identification number
2 RFID transponder (HF)
3QRcode
3.1.3 ATEX plate
II 2G Ex h IIC T4..T1 Gb
EX9A 045910 0003
2
1
Fig. 4 ATEX plate (EN 80079-36)
1 Explosion protection mark
2 Reference to ATEX additional instructions
10 ALLFUEL Series BA-2021.06 en-US 550 851 – 147-276/H

Layout and function
3.1.4 Pump type code
AFI - T 10 R 38 D 19US W226 E V F C B - NO 80
Fig. 5 Pump type code (example)
Posi-
tion Meaning
1Series
Version
-E Insert unit
-F Single unit with filter
-T Twin unit with filter
2
Omitted for individual units without filter (AFI)
Size
3
Theoretical flow rate Q in l/min at 1450 rpm and
46° pitch angle
Spindle pitch direction
4
R Right
5Spindle pitch angle in degrees
Bearing type6
DOutside antifriction bearing
7Non-heated, non-cooled, single-action mechanical
shaft seal
8 Material version
Version with electrically heated mechanical seal
and filter housing
9
Omitted in the unheated version
Type of installation
Vvertical
Hhorizontal
10
Appicable for individual units without filter (AFI),
omitted for version -E, -F, -T according to pos. 2
Flange
FCounter flange
AAdapter flange
11
Omitted for versions without counter flange or
adapter flange
Couplingformotorsizeaccordingtopos.15
Option if motor not included in the scope of delivery,
according to pos. 14
12
Omitted if motor in scope of delivery
Pump carrier for motor size according to pos. 15
Option if motor not included in the scope of delivery,
according to pos. 14
13
Omitted if motor in scope of delivery
No motor included in delivery contents14
Omitted if motor in scope of delivery
15 Motor size
Tab. 5 Pump type code
550 851 – 147-276/H BA-2021.06 en-US ALLFUEL Series 11

Layout and function
3.2 Layout
12 345
678 9
10
Fig. 6 Pump layout
1 Drive screw
2Idlerrotor
3 Casing insert
4Pumpcasing
5 Shaft seal
6 Bearing
7 Coupling
8 Pump carrier
9 Motor
10 Limit for heat insulation
12 ALLFUEL Series BA-2021.06 en-US 550 851 – 147-276/H

Layout and function
1
2
3
5
7
6
8
9
10
11
4
Fig.7 Layoutoftwinunitwithfilter
1 Ball valve
2 Filter
3 Motor
4 Pump carrier
5 Coupling
6 Bearing
7 Shaft seal
8Pumpcasing
9 Casing insert
10 Drive screw
11 Idler rotor
550 851 – 147-276/H BA-2021.06 en-US ALLFUEL Series 13

Layout and function
3.3 Shaft seals
3.3.1 Mechanical seals
Mechanical seals have functional leakage.
• Mechanical seal, standard version
– Uncooled, maintenance-free unbalanced mechanical
seal construction
3.4 Bearings and lubrication
• External antifriction bearing lubricated with grease accord-
ingtoDIN625
– Not capable of relubrication, lifetime grease fill
3.5 Auxiliary systems (heating)
The mechanical seal area can be electrically heated. This
allowsthemechanicalsealareatobepre-heatedwhenthe
pump is not running.
3.6 Hydraulic diagram
For twin unit with filter (AFI-T) only.
Fig. 8 Circuit diagram of twin unit with filter
1 Main and stand-by pump
2 Motor (910)
3 Ball valve (24)
4 Filter (480)
5 Check valve (335)
6 Compoundgaugewithstopvalve(360)
7 Pressure gauge with stop valve (361)
8 Pressure relief valve (330)
14 ALLFUEL Series BA-2021.06 en-US 550 851 – 147-276/H

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/unit on delivery and inspect it for trans-
port 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.
Fasten the lifting gear to the pump unit (see illustrations).
Fig. 9 Fastening the lifting gear to the pump unit
horizontally (as illustrated)
Fig. 10 Fastening the lifting gear to the pump unit vertically
or the filter unit with single pump (as illustrated)
Fig. 11 Fastening the lifting gear to the twin unit with filter
550 851 – 147-276/H BA-2021.06 en-US ALLFUEL Series 15

Transport, storage and disposal
4.2 Treatment for storage
The pump has not been treated for storage at the factory.
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.
4.2.1 Applying preservative to the inside
Spray the insert units with preservative and shrink-wrap
them in plastic film.
1. Close the suction-side flange with a blank flange.
2. Fillupthepumpwithpreservative.
3. Turn the shaft slowly against the pump’s sense of rotation.
4. Continue filling and turning until preservative escapes from
the discharge flange without bubbles.
5. Close the pressure-side flange with a blank flange.
6. Every 6 months:
– Renew the preservative if necessary.
4.2.2 Applying preservative to the outside
1. Apply preservative to all bare metal parts.
2. Every 6 months:
– Renew the preservative if necessary.
4.3 Storage
NOTE
Material damage due to inappropriate storage!
Treat and store the pump properly.
1. Seal all openings with blank 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 the 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 to seals due to wrong cleaning agents!
Ensure the cleaning agent does not corrode the seals.
1. Choose the cleaning agent according to the application.
(→9.2.4 Cleaning agents, Page 37).
2. Remove the preservative from all bare internal parts of the
pump.
3. Dispose of cleaning agents in accordance with local regu-
lations.
4. For storage times in excess of 6 months:
– Replace the elastomer parts made of EP rubber
(EPDM).
– Check all elastomer parts (O-rings, shaft seals) for
proper elasticity and replace them if necessary.
5. 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 escaping pumped liquid or
oil in accordance with local regulations.
– Neutralize residues of pumped liquid in the pump.
– Removing the preservative (→4.4 Removing the
preservative, Page 16).
Remove the plastic parts and dispose of them in accor-
dance with local regulations.
Dispose of the pump in accordance with local regulations.
16 ALLFUEL Series BA-2021.06 en-US 550 851 – 147-276/H

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 any covers or transport and screw plugs
until immediately before connecting the pipes to the pump.
5.1 Preparing the setup
5.1.1 Checking the ambient conditions
Make sure the required ambient conditions are fulfilled
(→9.2.1 Ambient conditions, Page 37).
5.1.2 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
5.1.3 Preparing the surface
Make sure the surface meets the following conditions:
–Level
– Clean (no oil, dust or other impurities)
– Capable of bearing the weight of the pump unit and all
operating forces
– The pump is stable and cannot tip over
5.1.4 Removing the preservative
If the pump is to be put into operation immediately after
setup and connection: Remove the preservative prior to
installation (→4.4 Removing the preservative, Page 16).
5.1.5 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!
Only install the heat insulation on the pump casing.
Install the heat insulation properly.
5.2 Setup
5.2.1 Set up with pump carrier
CAUTION
Air pockets in the pump and dry running can cause dam-
age
For horizontal setup, position the flange horizontally or
upward.
For horizontal setup, position the air release plug (160) hor-
izontally or upward.
For vertical setup, position the motor upward.
1. Lift the pump unit and set it down at the installation location
(→4.1 Transport, Page 15).
2. Install the pump unit (→setup drawing).
5.2.2 Setup with base
Pump units and pump filter units with a base are installed
vertically (motor at the top).
1. Lift the pump unit and set it down at the installation location
(→4.1 Transport, Page 15).
2. Install the pump unit (→setup drawing).
550 851 – 147-276/H BA-2021.06 en-US ALLFUEL Series 17

Setup and connection
5.3 Installing the motor
5.3.1 Installing the motor on pumps in flange versions
Onlynecessaryifthepumpunitisassembledonsite.
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. Smear a very thin coat of molybdenum disulfide (e.g.
Molykote) on the shaft ends of the pump and motor.
2. Insert the shaft keys.
3. Slip on the pump-side and motor-side coupling halves in
line.
– Without a mounting fixture: Remove the rubber buffers
and heat the coupling halves up to approximately
100 °C.
4. Tighten the grub screws on both coupling halves.
5. Lift the motor and position it on the pump carrier.
6. Tighten the motor bolts.
5.4 Planning the pipes
5.4.1 Specifying supports and flange connections
NOTE
Material damage due to excessive forces and torques
exerted by the piping on the pump!
Do not exceed the permissible values (→flange loads
according to EN ISO 14847)
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 due to corrosion.
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 line diameter is ≥as pos-
sible to the nominal outlet flange diameter.
– Recommended flowratespeed<3m/s
5.4.3 Specifying pipe lengths
B
A
Fig. 12 Straight pipe lengths upstream and downstream
of the pump (recommended)
A > 5 x nominal suction pipe diameter
B > 5 x nominal pressure line diameter
Recommendation: Provide long, straight pipes upstream
and downstream of the pump.
– This will improve the suction performance of 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 and direction along
the piping.
5.4.5 Discharging leakage
WARNING
Risk of injury and poisoning due to hazardous pumped
liquids!
Safely collect any leakage, then discharge and dispose of
it in accordance with environmental regulations.
1. Provide equipment for collecting and discharging leakage.
2. Ensure the free discharge of leakage.
18 ALLFUEL Series BA-2021.06 en-US 550 851 – 147-276/H

Setup and connection
5.4.6 Avoiding excessive pressure
WARNING
Risk of injury due to excessive pressure!
If no pressure relief valve is present: Provide an appropri-
ate safety valve in the pressure line.
NOTE
Material damage due to overheating of the pump!
If the return flow of the pressure relief valve flows directly
into the pump suction side or suction pipe: Monitor the
temperature.
1. Observe the operating instructions of the manufacturer.
2. Make sure the factory setting of the pressure relief valve
meets the requirements of the system.
3. Do not feed the return flow of the safety valve directly back
into the suction pipe.
5.4.7 Providing safety and control devices
(recommended)
Avoid impurities
Not necessary with filter units.
1. Install a dirt trap in the suction pipe (mesh size of 0.4 mm).
2. To monitor impurities, install a differential pressure gauge
with contact pressure gauge.
3. Provide a fine filter if necessary:
– Select the filter mesh, depending on the type, level of
dirt and discharge pressure.
Avoiding reverse running
Install a check valve between the outlet flange and the stop
valve to ensure the liquid does not flow back when the
pump is switched off.
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
Not necessary with filter units.
1. Provide pressure gauges for measurements in the suction
and pressure lines.
2. Provide for suction-side temperature measurements.
Monitoring leakage
Only necessary for hot or hazardous pumped liquids.
1. Provide leak monitoring equipment.
2. Safely collect any leakage (e.g. following a seal malfunc-
tion) and dispose of it.
550 851 – 147-276/H BA-2021.06 en-US ALLFUEL Series 19

Setup and connection
5.5 Connecting the pipes
5.5.1 Keeping the pipes clean
NOTE
Material damage due to impurities in the pump!
Make sure no impurities can enter the pump.
1. Flush all pipe 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.
4. On welded pipes: Remove the welding beads.
5.5.2 Installing the suction pipe
1. Remove the transport and screw plugs from the pump.
2. To avoid air pockets:
– For supply operation: Run the pipes with a continuous
downward slope to the pump.
3. Ensure no seals protrude inwards.
4. On wet pit installations: Observe the minimum immersion
depth (→technical description).
5.5.3 Installing the pressure line
1. Remove the transport and screw plugs from the pump.
2. To avoid air pockets:
– Run the pressure line with a continuous upward or
downward slope.
– Otherwise, include a vent valve at the highest point of
the pressure line.
3. Install the pressure line.
4. Ensure no seals protrude inwards.
5.5.4 Checking the 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.
5.6 Electrical connection
DANGER
Risk of death due to electric shock!
Have all electrical work carried out by qualified electricians
only.
5.6.1 Connecting the motor
Follow the instructions of the motor manufacturer.
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.
5.6.2 Connecting the heater
Observe the manufacturer’s specifications for the heater.
1. Connect the heater according to the connection diagram.
2. Make sure no danger arises due to electric power.
3. Install an EMERGENCY STOP switch.
5.7 Installing the coupling guard
Flanged drive
1. If present, install the coupling guard (two plates) on the
pump carrier.
20 ALLFUEL Series BA-2021.06 en-US 550 851 – 147-276/H