Allweiler Emtec Series Manual

1
Operating and Maintenance Instructions VM No.: 623.0004 GB
Edition: 07.00
Ident No.: 550 298
Screw pumps Retain
for future
Series use!
Order No.: Pump Ident. No.:
Machine No.: Pump Type:
Operating data, dimensions and other additional information can be found in the order–specific part of the
documentation.
These Operating and Maintenance
Instructions contain information from
thepumpmanufacturer.Theymayneed
to be supplemented by instructions of
the operator company for its personnel.
These instructions do not take account
of specific information relating to opera-
tion and maintenance of the process
plant into which the pump is integrated.
Such information can only be given by
the persons responsible for construc-
tion and planning of the plant (plant
manufacturer).
Such specific instructions relatingto
operation and maintenance of the
process plant into which the pump is
integrated have priority over the
instructions of the pump manufac-
turer. The plant manufacturer must
on principle observe the limits of
use!
Refer to the operating instructions of
the plant manufacturer!
Contents
1. General
2. Safety
3. Transportation and Intermediate
Storage
4. Description
5. Installation/Mounting
6. Start–up/Shutdown
7. Maintenance/Repair
8. Operating Faults, Causes and
Remedial Action
9. Associated Documentation
Important note:
This operating manual is to be supplemented
by the order–related informations.

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VM 623.0004 GB/07.00 –Ident–Nr. 550 298
1 General
1.1 Abbreviation
Theabbreviationofthescrewpumpissetupaccording
to the following schema, and is engraved on the type
plate.
Example:
Series
EMTEC 80 R 46 D 8.6 –W110111
Size = theoretical delivery
in [l/min] with normal pitch
and 1450 1/min
Direction of screw pitch
R = right
Angle of screw pitch [degrees]
Special design feature
D = Rolling bearing pre–mounted,
Mechanical seal uncooled/unheated
Shaft seal
Q = without (wet installation)
8.6 = Mechanical seal (dry installation)
Material code
1.2 Proper use
Information on proper use of the pumps is provided in
the technical data sheet.
The execution of the pump is precisely matched to the
operating conditions (see order data sheet).
Any subsequent modification to the
medium or the operating data must be
discussed and agreed with the manufacturer,
otherwise our liability for any faults that may arise will
be void.
1.3 Performance data
The exact performance data applicable to the pump
can be taken from the order data sheet and/or
acceptance test report, and are engraved on the name
plate.
The pressure data indicated there apply only to
approximated static pressure load. In the case of
dynamic alternating pressure load, consult the
manufacturer.
1.4 Warranty
Our warranty for shortcomings in the supply is laid
down in our delivery conditions. No liability will be
undertaken for damages caused by non–compliance
with the operating instructions and service conditions.
Ifatanylaterdatetheoperatingconditionschange(e.g.
different fluid conveyed, speed, viscosity, temperature
or supply conditions), it must be checked by us from
casetocaseandconfirmed,ifnecessary,thatthepump
is suited for those purposes. Where no special
agreements were made, pumps supplied by us may,
duringthewarrantyperiod,onlybeopenedorvariedby
us or our authorized contract service workshops;
otherwise our liability for any defects will cease.
1.5 Testing
Priortoleavingourfactory,allpumpsaresubjectedtoa
thorough test run and performance test on the test
stand. Only properly operating pumps, achieving the
performance assured by us, leave the factory.
Thus, compliance with the following operating
instructions ensures fault–free operation and full
delivery.
1.6 Availability
As a matter of principle, we recommend stocking
replacement pumps and withdrawable units (hydraulic
action system) where the supplied pumps are a
decisive factor in maintaining a production or delivery
process. In this way downtimes can be avoided, or
reduced to a minimum.

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VM 623.0004 GB/07.00 –Ident–Nr. 550 298
2Safety
These operating instructions contain basic safety
instructions for installation, operation and
maintenance.Itisthereforeessentialthattheyareread
byfittersandallspecialiststaffandcustomerpersonnel
prior to installation and start–up. They must always be
kept at hand at the place of installation.
The special safety instructions contained in the other
chapters must be observed in addition to the general
safety instructions in this chapter.
2.1 Identification of safety instructions in the
operating manual
The safety instructions contained in these operating
instructions which represent a danger to personnel if
not complied with are specially marked by the general
danger symbol:
Warning symbol
as per DIN 4844–W9
Warning of danger from electric voltage is indicated as
follows:
Warning symbol
as per DIN 4844–W8.
Instructions which are essential to avoid endangering
the machine and its operation are marked by the word
ATTENTION
Instructions affixed directly to the machine such as
SDirectional markers
SSigns for fluid connections
must always be observed and maintained in fully
legible condition at all times.
2.2 Personnel qualification and training
The operating, maintenance, inspection and mounting
personnelmustbeappropriatelyqualifiedfortheduties
assigned to them. The scope of their responsibilities,
competency and supervisory duties must be closely
controlledbythecustomer.Ifthepersonneldonothave
the required knowledge, they must be trained and
instructed. If required, this may be provided by the
manufacturer/supplier on behalf of the customer. The
customer must additionally ensure that personnel fully
understand the content of the operating instructions.
2.3 Dangers in the event of non–compliance with
safety instructions
Failuretocomplywiththesafetyinstructionsmayresult
in danger to persons, and place the environment and
the machine at risk. Non–compliance with the safety
instructions will lead to the loss of any claims for
damages.
Non–compliance may result in the following dangers:
SFailure of important functions of the plant
SFailure of specified methods for maintenance and
servicing
SDanger to persons resulting from electrical,
mechanical and chemical effects
SDangertotheenvironmentresultingfromleakageof
hazardous substances
2.4 Responsible working practices
The safety instructions contained in these operating
instructions, current national accident prevention
regulations, as well as internal working, operating and
safety rules of the customer, must be observed.
2.5 Safety instructions for the user/operator
SHot or cold machine parts representing a danger
must be protected against accidental contact on
site.
SProtection against accidental contact for moving
parts (such as the coupling) must not be removed
while the machine is in operation.
SWhen operating pump aggregates in a dust–laden
environment (e.g. milling, chipboard manufacture,
bakeries), the surfaces of the pumps and motors
must be cleaned at regular intervals, depending on
local conditions, in order to maintain the cooling
effect and eliminate the possibility of spontaneous
combustion. Please also see explosion protection
regulations (ZH 1/10).
SLeakage (e.g. from the shaft seal) of hazardous
substances being handled, such as explosive, toxic
or hot materials, must be discharged in such a way
that no danger to persons or the environment is
created. Legal regulations must be observed.
SDangers from electrical energy must be eliminated.
For details in this regard, please refer to VDE and
local power company regulations.

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VM 623.0004 GB/07.00 –Ident–Nr. 550 298
2.6 Safety instructions for maintenance, inspection
and installation
The operating company must ensure that all
maintenance, inspection and installation tasks are
performed by authorized and qualified specialist
personnel who have thoroughly studied the operating
instructions.
Workon the machine is onlytobecarried out when the
machine is at a standstill. The procedure for shutting
down the machine described in the operating
instructions must always be followed.
Pumps or aggregates handling fluids which are
detrimental to health must be decontaminated. All
safety and protective devices must immediately be
refitted and made operational on completion of the
work.
The instructions under Section 6.1, ”Preparation for
start–up”, must be observed before restarting.
2.7 Unauthorized conversion and production of
replacement parts
Conversion or modification of the machines is only
permissible after consultation with the manufacturer.
Original replacement parts and accessories approved
by the manufacturer are intrinsic to safe operation. If
other parts are used the manufacturer cannot be held
liable for the consequences.
2.8 Unacceptable modes of operation
The operational safety of the machine supplied is only
ensuredwhenitisusedinaccordancewithSection1of
theoperatinginstructions.Thelimitvaluesgivenonthe
data sheet must not be exceeded under any
circumstances.
3 Transportation and Intermediate Stor-
age
3.1 Packaging
Attentionmustbepaidtothefigurativemarkingsonthe
packaging.
Thesuctionandpressuresideandallauxiliaryconnec-
tions must always be closed during transportation and
storage. The coverings must only be removed im-
mediately before connecting the pipeline.
3.2 Transportation
The pump or pump aggregate is to be safely trans-
ported to the place of installation, if required by means
of lifting gear.
Theregulations for lifting loads inaccordance with
VBG 9a must be observed. Crane and sling equip-
ment must be adequately dimensioned. Sling
equipment must not be secured to the lifting eyes
of the motor, except as additional protection
against overturning in the event of nose–heavi-
ness.
Transportation to and at the installation site
Make sure that the unit is transported safely and in a
stable position. Overturning due to nose–heaviness
must be prevented.
Completeaggregates mustbe transported tothe place
of installation as shown in the illustration.
Fig. 3.1: Transportationofahorizontallymountedpump
aggregate
In the case of vertically and horizontally mounted
flanged pump aggregates, it is advisable to attach the
cables to the wall/foot lantern or intermediate fitting
lantern (not shown).
Transport damage
Check the pump for damage on receipt.
Anydamage detectedmustbe notifiedim-
mediately.

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VM 623.0004 GB/07.00 –Ident–Nr. 550 298
3.3 Preservation and storage of the screw pumps
3.3.1 Preservation
In the case of storage or prolonged standstill, the
pumps must be protected against corrosion. In those
cases, an outside and inside preservation is to be
provided. The durability of the protection against
corrosion, which is limited in time, depends on the
composition of the preservative to be applied and the
storage conditions.
Under normal circumstances the pumps
have no special preservative.
At an additional charge we can, however, supply
pumpsandreplacementparts ex factory with a preser-
vative adequate to the planned storage period.
Wewill bepleased to specify suitable preservativesfor
you on request.
3.3.1.1 Outside preservation
Theoutside preservative shouldbe appliedby painting
or spraying with a spray gun.
Points of preservation:
All bright and unvarnished parts (e.g. shaft ends, cou-
plings, flange facings, valve and manometer connec-
tions).
3.3.1.2 Inside preservation
Thepreservativeistobeappliedbyfillingthepump.For
thesepurposes,thesuctionsideofthepumpmustfirst
be closed with a dummy flange. During filling, the
pressure flange must be on a higher level than the
suctionflange.Duringthefillingprocess,theshaftmust
be slowly cranked against the direction of rotation.
Fillingmustbecontinueduntilthepreservativereaches
the sealing strip of the delivery flange, bubble–free.
Then the outlet side is to be closed with a dummy
flange.
Note: Not required for pumps made of stainless ma-
terials.
Points of preservation:
All bright parts inside the pump (e.g. pump casing in-
side, screw spindles, ball bearings, pressure–relief
valves).
3.3.1.3 Monitoring of preservation
In the event of prolonged storage, the preservation of
the pump must be checked by the customer at regular
intervals.
Every six months the pump level must be checked; if
necessary, preservative must be topped up to the
sealing strip on the pressure flange.
At the same time, the packing must be checked for
destruction, and repaired if necessary.
Note: Liability for damages caused by improper
preservation cannot be assumed by us.
3.3.1.4 Depreservation
Prior to setting the pump in motion, the preservative
applied must be removed.
Environmentally compatible disposal must be
ensured.
The preservative applied for inside preservation can
normallyberemovedbyflushingthepumpwiththefluid
to be conveyed.
Alternative, suitable solvents may be applied for
removing the inside and outside preservation.
Appropriate solvents are for example: petroleum,
benzene,Diesel fuel, spirit, alkalis (industrialcleaners)
or any other wax solvents. Steam jet cleaning devices
with appropriate admixtures can also be used (allow
wax solvent to act beforehand).
Prior to start–up after prolonged storage,
all elastomers (O–rings, shaft seals) must
be checked for their elasticity of shape. Embrittled
elastomers must be exchanged. Elastomers of
ethylene–propylene rubber (EPDM) must always be
replaced. The pump must be filled with fluid to prevent
seizing of the components. A pressure–relief valve
attached or fitted in the pipeline must be checked for
passage.
Note: If on the plant side, the pipelines, (oil) tanks or
other parts are wetted with paraffin–containing
preservative, the entire plant must be depreserved as
paraffin isdetrimental to theair separating capabilityof
oil. This may result in unsteady operation of the pump
and loud noise.
3.3.2 Storage
During storage of the pump, the suction and outlet
branches and all other supply and discharge branches
must always be closed with dummy flanges or dummy
plugs.
Storage should be in a dry, dust–free room. During
storage, the pump should be cranked at least once a
month.Duringthisprocess, partssuchastheshaftand
bearings should change their position.

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VM 623.0004 GB/07.00 –Ident–Nr. 550 298
4 Description
4.1 Structural design
Three–screw pumps in flange design form, with a
double–threaded driving spindle and two double–
threaded idler spindles, enclosed in a rotor housing
with narrow running clearance.
4.1.1 Bearing and lubrication
By a pre–mounted, greased groove ball bearing to
DIN 625, not regreasable, with sealing washers on
both sides and lifetime grease filling.
4.1.2 Shaft seal
SMechanical seal, design 8.6
(Standard for dry installation):
Uncooled, maintenance–free mechanical seal of
the unbalanced type.
Materials of the mechanical seal:
Rotating seal ring: Silicon carbide
Stationary seal ring: Silicon carbide
Auxiliary gaskets: Viton
Spring: CrNiMo steel
Metal parts: CrNiMo steel
Swithout shaft seal, design Q
(Standard for wet installation)
4.1.3 Pipeline and auxiliary connections
For execution, branch positions and dimensions of all
connections, see order–specific installation drawing.
4.1.4 Pressure relief valve
For safety reasons, screw pumps must generally be
equipped with a pressure relief valve.
Mostpumpsarealreadyequippedwithapressurerelief
valvewhen theyleave the factory. The standardtrigger
pressure of this valve is approximately 10% above the
operating pressure.
Pumpsthataresuppliedwithoutapressurereliefvalve
must be provided with a suitable safety valve by the
customer. The safety valve must be fitted in the dis-
chargepipelinebetweenthepumpandthefirstshut–off
device.
4.2 Mode of operation
Through the suction connection, the fluid is conveyed
into the suction chamber of the pump. From there the
fluid flows into the spindle chambers, which are
constantly formed by the rotary motion at the spindle
end on the suction side. By the translatory rotary
motion,thechambersfilledwiththe fluidmovefromthe
suction side to the outlet side. During this process the
closed chamber volume does not change. At the
spindle end on the outlet side the chamber opens
towards the delivery chamber. The fluid is steadily
pushed out into the delivery chamber from where it is
transported, through the pressure connection, into the
pressure pipeline.
The axial thrust acting on the faces of the profile flanks
on the outlet side is hydraulically balanced by an
appropriate dimensioning of the compensating piston
of the driving spindles and the compensating journals
of the idler spindles. Thus the bearing is relieved of the
hydraulic axial thrust.
The idler spindles are hydraulically driven by means of
appropriate dimensioning of the spindles. The torque
resulting from the friction is transmitted via the profile
flanks.
Asaresultoftheconstantchambervolumethemedium
inside the pump is transported, almost entirely free of
turbulence and squeezing, from the suction side to the
outlet side.
The structural design and mode of operation of the
screw pump ensure a very low noise level and an
almost pulsation–free delivery.
4.3 Construction of the pump aggregate
4.3.1 Drive
Thepumpscanbe directlycoupledwith electricmotors
of the most varied designs, or any other prime movers.
In most cases, surface–cooled three–phase squirrel
cageinduction motorsare usedas drivingmotors, type
IMV1,classofprotectionIP54toIECstandard,classB
insulation, outputs and speeds to DIN 42 677.
The exact motor data are to be found on the order data
sheet.
4.3.2 Shaft coupling and contact protection
Powertransmissioniseffectedviaaflexiblecouplingto
DIN 740. Additional radial forces must not act on the
driving spindle.
Protection against accidental protection to EN 809 is
provided where a pump bracket or fitting lantern is
supplied as part of the product package.
According to accident prevention regulations, the
pump must only be operated with a protection
against accidental contact as per EN 809.
Ifnocontactprotectionisprovided,itmust be attached
by the operator.
4.3.3 Pump bracket/Foot angle
Pump brackets and foot angles are available for
horizontal or vertical mounting with V1 motors.
4.3.4 Fitting lantern
Fitting in the fluid tank is enabled by using fitting
lanterns.
Note: A fitting lantern attached by the operator must
have bore holes to drain off the fluid medium.
4.3.5 Base plate/Foot angle
Suitable foot angles are available for mounting of the
flange pump for horizontal assembly with B3 motors.
Base plates can be provided in cast or steel design.

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VM 623.0004 GB/07.00 –Ident–Nr. 550 298
5 Installation/Mounting
5.1 Installation
For installation methods and locations, please see in-
stallation drawing.
Other methods of installation are not permissible
without prior consultation with the manufacturer.
5.1.1 Place of installation
Temperature: min. –20 °C
max. +40 °C
relative air humidity:
permanent max. 85 %
temporary max. 100 %
Installation height: max. 1000 m above NN
For data differing from this, please consult the manu-
facturer. Intensive vibrations in the vicinity of the
pumpunitcanleadtobearingdamageand
must therefore be avoided.
5.1.2 Protective devices
In order to prevent injuries due to burns, at pumping
liquid temperatures higher than 60°C protective de-
vices in accordance with EN 809 must be provided on
site.
5.2 Foundation
5.2.1 General
Thefoundationmaybeafloor/concretebaseoraload–
bearing steel foundation frame.
The foundations must be constructed in
suchawaythattheycantaketheweightof
the pump unit and all operating forces that occur.
5.2.2 Characteristics of a steel foundation frame
Asteelfoundation framemustbeconstructedin sucha
way that pump feet or base plate are supported evenly
and can be secured with screw fixings.
If the base plate is only supported at four
pointsthe pump aggregatewill hang down
in the middle. This will affect the alignment of the cou-
pling and may also lead to severe noise being gener-
ated.
5.2.3 Characteristics of a floor/concrete foundation
The foundation must be horizontal, flat and clean, and
be capable of bearing the full load upon it.
Note: Concrete foundations must be executed with
standardconcreteofstrengthclassB25asaminimum.
5.3 Alignment of the pump aggregate
The pump aggregate must be aligned to its pre–set
height and system dimensions. This is done usingsui–
tablesteelshims,arrangeddirectlyadjacenttoeachfi–
xing bolt.
The overall height of the steel shims is determined by
the established system dimensions of the plant. The
steel shims and the base plate must be positioned
evenly and securely.
If the fixing holes are more than 750 mm apart, we re–
commend fitting additional steel shims in the middle of
the base plate.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Steel shims Foundation
Base plate
==
> 750
Fig. 5.1: Alignment with steel shims
Horizontal alignment of the aggregate is produced by
way of flat–machined surfaces on the pump using a
machinespirit level. Measurements are taken in longi–
tudinal and transverse directions of the pump aggre–
gate.
Permissible deviation: max. 1 mm per 1 m length.
5.3.1 Fixing the pump aggregate
Inordertopreventdeformationofthebaseplate/pump,
this must first of all be screwed tightly at three points.
Before tightening the rest of the screws, spacers
should again be positioned around the screw, in order
to balance out the unevenness of the seating.
The prescribed tightening torque must be
observed.
Precisedetailsontheshapeanddimensionofthefixing
are provided in the installation drawing.
5.3.2 Checking the alignment
After aligning and tightening the screws, it must be
possible to turn the pump and drive by hand, without
any strain.
Note: The pump unit should not be welded to the base
for technical installation reasons.
5.4 Checking the coupling alignment
5.4.1 Checking the coupling alignment in case of hori-
zontal setup on base plate (if used)
A complete delivered pump aggregate has been care–
fully assembled at the factory. After proper installation,
and prior to start–up of the pump aggregate, the align–
ment of the coupling must be checked.
The check can be made with a straight–edge and a
feelergauge,orwithothersuitableequipment(such as
a laser alignment device).
Themeasurementsaretakenintwoplanes,eachoffset
by 90_, on the circumference of the coupling.

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VM 623.0004 GB/07.00 –Ident–Nr. 550 298
If a height, lateral or angle offset is detected between
the two coupling halves, the drive motor should be re–
aligned such that the coupling halves are flush with
each other (level out with flat packing shims as neces–
sary).
The gap between the two coupling halves must be the
same all round the circumference of the coupling. The
specified gap is shown in the installation diagram.
The spacing between the straight–edge laid over both
coupling halves and the respective shaft must be the
same all round the circumference.
Straight–edge
Feeler gauge
Figure 5.2: Alignment of the coupling with
straight–edge and fee–ler gauge
For couplings with a distance piece (removable coup-
lings) the alignment of the coupling can be checked
with dial gauges.
Figure 5.3: Alignment of the coupling with dial gauges
Note: The permissible axial and radial deviation,
measured on the front face of the coupling and the
coupling circumference respectively, may be max.
0.1 mm, but as far as possible should be kept below
0.05 mm.
Whe the fixing bolts have been aligned and tightened
the pump/drive motor unit must be able to be spun by
hand without pressure points.
Out–of–flush errors on the coupling may
lead to heavier wear of the coupling, the
anti–frictionbearingandtheshaftseal,andevencause
the shaft end to be torn off.
5.4.2 Coupling alignment in case of flanged aggregates
(if used)
Inthecaseofpumpswithflangeddrivemotor,thepump
and motor are precisely centered in the lantern. Align-
ment or re–alignment of the coupling is not requi–red.
Note: Improper handling, e.g. during transportation,
may impair the alignment between the pump and the
motor. In this case the pump and the motor must be re-
turned to the factory for checking.
5.4.3 Coupling alignment of special designed couplings
(if used)
Refer to the operating instructions of the coupling
manufacturer.
5.5 Assembly of pump and drive motor
If the aggregate is only assembled at the place of use,
the following worksteps take place:
1. Coat the pump and motor shaft ends with a fine film
of molybdenum disulfide (e.g. Molykote) and insert
keys.
2. Pushonthe couplinghalves onthe pumpandmotor
side with the aid of a pusher device.
Refer to Assembling Instruction VM 623.0004–1/...
If no puller is available, heating the coupling halves
to approx. 100°C (without rubber buffer) facilitates
pushing. The possibility of shock and stress on
the pump and drive motor components
must be eliminated.
3. Tighten the grub screw on both coupling hubs.
4. When assembling the pump and motor, make sure
the specified gap between the coupling halves is
maintained.Thepumpcasingupfromsize210must
be supported additionally at the site
(see installation drawing).
5. In the case of horizontally mounted pump aggre-
gatesfixedonabaseplate ordirectlyonthefounda-
tion, the coupling must be aligned as described in
Section 5.4.
In the case of pump aggregates with flanged motor,
the coupling does not need to be re–aligned.
6. Mount the contact protection.
According to accident prevention regulations, the
pump must only be operated with a protection
against accidental contact.
5.6 Space required for maintenance and repair
The pump must be accessible from all
sides in order to be able to carry out
necessary visual inspections.
Adequate space must be provided for maintenance
and repair work, in particular for removal of the drive
motor or of the complete pump aggregate. It must also
be ensured that all pipelines can be attached and
removed without hindrance.

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VM 623.0004 GB/07.00 –Ident–Nr. 550 298
5.7 Laying the pipelines
5.7.1 Nominal widths
If possible, the nominal widths of the suction and
pressure pipelines should be rated so that the rate of
flowdoesnotexceedamaximumof1m/sinthesuction
pipeline and 3 m/s in the pressure pipeline. If possible,
suction pipelines laid ”uphill”are to be avoided.
5.7.2 Change of cross–sections and directions
Sudden changes of cross–sections and directions, as
well as hairpin bends, are to be avoided.
5.7.3 Supports and flange connections
The pipelines must be connected to the pump,
stress–free.Theymustbesupportedclosetothepump
and must allow easy screwing–on to avoid twisting.
When the connections are loosened the pipeline must
neither be slanted nor springing, nor must it be under
pressure.
Any thermal stresses occurring on the pipelines must
be kept away from the pump by suitable means, e.g.
installing compensators.
5.7.4 Cleaning pipelines prior to attachment
Priorto assembly,allpipeline parts andvalves must be
thoroughly cleaned; especially in the case of welded
pipelines, burrs and welding beads must be removed.
Flange gaskets must not protrude inwards. Blanking
flanges,plugs,protectivefilmand/orprotectivepainton
flanges and seals must be removed completely.
5.7.4.1 Inlet/suction conditions (NPSH)
Toensurefault–freecontinuousoperation,theinletand
suction conditions of the plant must be appropriately
adjusted to the pump demand (NPSHreq.)
The service condition is fulfilled when the plant NPSH
value (NPSHavail.) is above the pump NPSH
(NPSHreq.). The NPSHreq. is given in the
characteristic sheets of the respective pumps
When pumping air–laden or volatile
liquids,particular attentionmustbe paid to
the NPSH requirements of the plant.
5.7.5 Stop valves
Stop valves are to be installed in the suction and
pressure pipelines close to the pump.
5.7.6 Pressure–relief valve
See Section 4.1 ...
5.7.7 Check valve
It is recommended to install a check valve between the
pressure connection of the pump and the stop valve in
ordertopreventthepumpfromrunningdrywhenitisat
a standstill and the pressure stop valve is open.
5.7.8 Vent valve
Aventvalvemustbeprovidedatthehighestpointinthe
pressure pipeline.
5.7.9 Fluid tank
The tank must be designed so that air bubbles formed
in the plant are separated from the fluid and not drawn
in again by the pump.
5.7.10 Filtering
To protect the pump against coarse dirt contamination,
werecommendas amatterofprincipleinstalling afilter
in the suction pipeline, mesh width 0.6 mm.
Note: The service life of the pump is decisively
influenced by the degree of dirt contamination of the
fluid being conveyed, that is, by the number, size and
hardness of the abrasive components.
5.8 Safety and control devices
5.8.1 Manometers
Suitable pressure gauges are to be installed in the
suction and pressure pipelines.
5.8.2 Safety device in the pressure pipeline
For pumps delivered without a pressure–relief valve,
an overload protection must be provided in the control,
ora pressure–reliefvalve (returnvalve) inthe pressure
pipeline (see separate Operating Instructions).
5.9 Electrical connections
The power supply cables of the coupled drive motor
must be connected by a trained electrician, according
to the motor manufacturer’s circuit diagram. The
applicable VDE regulations and local power company
rules must be observed.
Danger from electrical energy must be eliminated.

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VM 623.0004 GB/07.00 –Ident–Nr. 550 298
6 Start–up/Shutdown
6.1 Preparation for start–up
6.1.1 Filling the pump with fluid
Prior to initial operation, the screw pump
mustbefilledwithfluidandbled.Thisatthe
same time provides the spindles with the sealing re-
quired for suction.
The pump must not run dry.
Before filling, the operator must ensure
careful and thorough rinsing of the pump if
the fluid to be conveyed is not chemically compatible
with the test medium (see performance test report).
Thefluidisfilledthroughaboreholeinthepumpcasing
or via the pressure pipeline. The pump must be filled
with fluid until the fluid emerges free from air.
In the case of immersion pump aggregates the filling
levelmustensureadequatecoveringoftheinletrimbe-
fore and during operation.
During bleeding of the pump and the plant, hazardous
or environmentally harmful fluid and gas emerging
must be safely collected and discharged.
6.1.2 Control of drive motor direction of rotation
The direction of rotation of the motor must match the
direction of rotation arrow on the pump. The motor can
be briefly switched on with the suction and pressure
valves open to check the direction of rotation. If the
direction of rotation is wrong there is no pump suction.
Thisdamagesthepump.Thedirectionofrotationofthe
three–phase motor can be reversed by swapping any
two phases.If the direction of rotation is to be checked
beforethepumpisfilledwithfluid,thedrive
motormustbe disconnectedfromthe pump.Thepump
must not run dry.
6.2 Start–up
6.2.1 Starting
1. Prior to starting, the stop valves in the suction and
pressure pipelines must be completely opened.
2. Where the pump is fitted with a pressure–relief
valve, it is set on our test panel to respond 10%
above the operating pressure. The opening pres-
surecan be altered within narrow limitsbymeans of
an adjusting screw. The installation of a pressure–
relief valve is always required when an impermissi-
ble pressure rise is possible, due to a stop device or
throttle point in the pressure pipeline for example.
When starting and stopping the pump
under pressure, make sure that the
speed–and viscosity–dependent pressure load is
not exceeded.
If this is not ensured, the pump must be started and
stopped at zero pressure. This also applies to
pumps with speed–controlled drive motors.
3. During starting, a vent valve installed on the outlet
sideof theplant must beopened untilthe air hases-
capedfromthesuctionsideofthepump.Assoonas
fluid emerges the vent valve can be closed. The
pump is self–priming and is automatically vented
without counter–pressure.
4. The fluid level in the tank must be checked. It must
be ensured that, when the plant is running, the fluid
level in the tank does not fall below the minimum
limit. Top up fluid as necessary.
6.2.2 Drive
Switch on the motor.
Payattentiontoproduct–specificcharacteristics.Refer
to the operating instructions of the drive motor
manufacturer.
6.2.3 Checking the delivery values
When the motor has reached its operating speed, the
inlet pressure and outlet pressure of the pump must be
checked using manometers.
The motor must not be overloaded. The current con-
sumptioncanbecheckedwithanammeter. Inthiscon-
nection,the temperature and viscosity of the fluid must
also be checked. The readings must be checked
against the layout or acceptance test report.
The return motion from the safety valve
must not be led directly into the suction
line.Circulatory operation must be avoided.Prolonged
circulatory operation will lead to unacceptable heating
ofthe pumpedliquid, whichcan resultin damagetothe
pump. At no time may the permitted maximum
temperature be exceeded. Sudden tem-
perature changes are to be avoided. Within the per-
mitted operating temperature range, the temperature
gradient may not exceed 2°C/min.

11
VM 623.0004 GB/07.00 –Ident–Nr. 550 298
6.3 Shutdown
SDrive
Switchoffthemotor.Makesurethepumprunsdown
smoothly and evenly.
SInlet line
Close stop valve in inlet line.
SPressure pipeline
Ifanon–returnvalveisinstalledinthepressurepipe-
line, the stop valve can remain open. Without non–
return valve, the stop valve must be closed.
6.4 Measures in the event of standstills
Pumped liquid
... Measures in the event of
brief standstill Measures in the event of
prolonged standstill
May solidify
+
has a preservative effect ÀHear or drain pump Drain pump
May solidify
+
does not have a preserva-
tive effect Hear or drain pump Drain and preserve pump
À
Does not solidify
+
has a preservative effect
À
– –
Does not solidify
+
does not have a preserva-
tive effect –Drain and preserve pump
À
ÀSee section 3.3

12
VM 623.0004 GB/07.00 –Ident–Nr. 550 298
7 Maintenance/Repair
7.1 Maintenance
SThe instructions in Section 2, Safety, must be
observed in maintenance and repair work.
SRegular monitoring and maintenance of the pump
and the drive motor are essential for optimum ser-
vice life and safety.
7.1.1 General monitoring
1. The pump must not run dry.
2. The drive motor must not be overloaded.
3. The suction and pressure pipelines must be
checked for leaks. Air must be prevented from
entering the delivery system.
4. The shaft seal must have no inadmissible leakage.
5. Changes to the normal operating data may indicate
faults. The causes must be established.
6. Installed standby pumps must be started up once a
week.
7. Any additional devices on the pump/shaft seal must
be operated and monitored in accordance with re-
gulations.
7.1.2 Maintenance of components
7.1.2.1 Bearing
The built–in groove ball bearing is maintenance–free.
The bearing is designed for a service life of approx.
24,000 hours under normal operating conditions. The
actual usable life may be lower, due to intermittent
operation, high temperature, low viscosity or the like.
The running noises and the temperature in the bearing
area must be checked at regular intervals. We recom-
mend monitoring bearings by means of shock pulse
measurements.If damage toa bearing isdetected,the
bearing must be replaced.
The bearing area can become very hot.
Risk of burning if touched!
As a precautionary measure, we recommend that
the groove ball bearing is replaced every 2 years.
7.1.2.2 Shaft seal
The shaft is either sealed by mechanical seal (dry in-
stallation) or does not have a shaft seal (wet installa-
tion).
SMechanical seal
The built–in mechanical seal is maintenance–free.
Amaximumdrippingrateof10g/hmayoccurduring
operation and is normal. If the dripping is heavier,
the shaft seal must be replaced.
A defective shaft seal can cause uncontrolled dis-
charge of pumping liquid.
This constitutes a hazard to people (possibility of
spraying liquid) and to the environment!
7.1.2.3 Pressure–relief valve
Pressure–relief valves must be checked from time to
time, in particular after prolonged downtimes, for pas-
sage and functioning. Leaking pressure–relief valves
may cause damage to the pump. Damaged parts
should be replaced or repaired as necessary.
7.1.2.4 Coupling
The alignment of the coupling and the condition of the
flexibleelements in thecoupling should be checkedaf-
ter initial start–up and at regular intervals.
Note: Worn flexible elements must be replaced.
7.1.2.5 Drive
Refer to the operating instructions of the motor
manufacturer.
7.2 Repair
General
Thesystemoperatorisresponsibleforensuringthatin-
struction in safety is provided. The personnel must be
made aware of all hazards that can arise in connection
with the pumped liquid or the plant.
Mounting and repair work
TrainedService fitters areavailable on requesttocarry
out mounting and repair work.
For all repairs, it must be ensured that the pump is de-
pressurised, completely drained and cool. The motor
must be protected against unintended switching on.
We must refuse acceptance of repair work on pumps
filled with fluid, for the protection of our staff and for
environmental reasons. The expenditures for disposal
with respect to the environment are to be carry by the
customer/operating company.
Hazardous substances
Where repairs are to be carried out on pumps which
have been operated with hazardous substances À
and/or environmentally harmful media, the
customer/operator must inform its own personnel on
site,or our personnel whererepairsare returned to our
factory or a service workshop, without being
specifically requested to do so.
Together with the request for a Service fitter a
verificationof delivery material,forexample in theform
of a DIN safety data sheet, must be submitted to us.
Alternatively, you can request a certificate of safety
(form no. 448/191) from our Service department, filling
itouttruthfully, correctlyandinfull.Sendthecompleted
form to the center commissioned with carrying out the
repair, or hand it to our Service fitter.

13
VM 623.0004 GB/07.00 –Ident–Nr. 550 298
ÀHazardous substances are:
SToxic substances
SHealth–endangering substances
SCorrosive substances
SIrritants
SExplosive substances
SFire–inducing substances
SHighly flammable, easily flammable and normally
flammable substances
SCarcinogenic substances
SSubstances impairing fertility
SGenetically distorting substances
SSubstances in other ways hazardous to humans
Pumps or units which pump hazardous substances or
substances that are dangerous to the environment
must be completely decontaminated.
7.2.1 Dismounting the screw pump
Beforedismounting,thefollowingworkmustbecarried
out:
SThe power supply cable must be disconnected from
the motor by an authorized electrician. Electrical
danger must be eliminated! The motor must be
secured against being switched on.
SClose all stop devices in the suction and pressure
pipelines.
SDrain the fluid in flowable condition from the pump.
Note: Use a collecting tank.
SHazardous substances and/or environmentally
harmful media must be drained off and collected
such that no danger to life and limb is created.
Environmentally compatible disposal must be
ensured.
SThe pump must be depressurized and drained.
SAllow the pump and motor to cool to ambient
temperature.
SRemove the manometer cables, manometers and
retaining brackets.
SRemove the contact protection.
SRemove the motor from the base plate or pump
bracket where appropriate.
Note: Use suitable lifting gear.
SRemoveimmersionpumpaggregatesfromthetank.
SRemove supply/suction and pressure pipelines as
appropriate.
SLoosenthefasteningandremovethepumpfromthe
base plate or pump bracket.
Note: Use suitable lifting gear.
The pump must be dismounted by a qualified
technician using the pertaining drawings.
Toprevent damage, it is especially important to ensure
that the components are dismounted concentrically
and that they are not tilted.
Dismounting instructions:
SThe fitting position of all components must be accu-
rately marked before dismounting.
7.2.2 Mounting the screw pump
Beforeremountingcheck allparts forwear
and aging and, as necessary, replace with
original replacement parts.
Clean all parts before mounting. Always fit new
gaskets.
The pump must be mounted by a qualified techni-
cianusingthepertainingdrawings.Theprescribed
tightening torque must be observed.
Toprevent damage, it is especially important to ensure
that the components are mounted concentrically and
that they are not tilted.
Mounting instructions:
SThe markings applied when dismounting must be
observed.Thecomponentsmustbeputbackintheir
original fitting position.
SAftertighteningthescrewsitmustbepossibletoturn
the pump by hand without straining points.
7.2.3 Tightening torque
Note: With poor and lightly greased surfaces, the va-
lues must be increased by 10–15%, in order to reach
the required performance.
Thread Qualtity Tightening
torque
[Nm]
M 4
M 6
M 8
M 10
M 12
M 16
M 20
M 24
M 27
M 30
5.6
1,1
3,9
9,8
18,6
32,3
78,4
156,8
289,1
426,3
578,2
M 4
M 6
M 8
M 10
M 12
M 16
M 20
M 24
M 27
M 30
8.8
2,5
8,8
21,6
43,1
73,5
181,3
352,8
661,5
975,1
1323,0

14
VM 623.0004 GB/07.00 –Ident–Nr. 550 298
When the screw pump has been mounted the
following work must be carried out:
SAlign coupling (see Section 5.4).
SAttach supply/suction and pressure pipelines.
SAttach manometer lines, manometers and brackets
to pump.
SAttach contact protection.
SThe power supply cable must be connected to the
motorbyanauthorizedelectrician.Electricaldanger
must be eliminated! Pay attention to direction of
rotation.
SFill pump with fluid.
Start up pump as per instructions in Section 6.
7.3 Replacement parts/spare parts
The parts marked with footnote Àin the parts list can
be provided as replacement/spare parts.
However, for operational safety reasons, we recom-
mend you always stock a complete standby pump.
The advantage is that in the event of a fault or damage
the standby unit can replace the non–functioning unit
quickly and without great effort.
When ordering spare and replacement parts, besides
thepart number, denomination andquantity,thefol-
lowing should also be quoted:
Pump abbreviation,
Pump number,
Year of construction.
This information is engraved on the rating plate of the
pump.

15
VM 623.0004 GB/07.00 –Ident–Nr. 550 298
8 Operating Faults, Causes and Remedial Action
8.1 Faults with reference number for cause and remedial action
The table below is intended as a guide to identifying faults and their possible causes. Faults relating to the pressure–relief
valve are listed separately.
If faults occur which are not listed here, or which cannot be traced back to the listed causes, we recommend consulting the
factory, or one of our branch offices or sales offices.
The pump must be depressurized and drained when faults are being rectified.
Screw pump faults Reference numbers for cause and remedial action
No pump suction and no delivery 1, 2, 3, 4, 5, 11
Delivery too low 2, 6, 7, 8, 9, 10, 11
Pump operates noisily 4, 5, 6, 7, 8, 10, 11, 12, 13
Irregular delivery 6, 7, 10
Pump gets too warm 6, 7, 11, 14, 16
Pump is seized 14, 15, 16
Motor overload 6, 13, 14, 15, 16
Pressure–relief valve faults Reference numbers for cause and remedial action
Delivery pressure drops 17
Pressure–relief valve does not open 18
Pressure–relief valve does not close 19
Pressure–relief valve knocks 20
8.2 Causes and remedial action
Ref. no.: Cause Remedial action
1Pump not filled with fluid before initial operation. Fill pump with fluid.
2Stop valves/sliders not open or only partially
open. Fully open stop valves/sliders during operation.
3Motor direction of rotation wrong. The direction of rotation of the motor must match the direction
of rotation arrow on the pump. The direction of rotation can be
reversed by swapping any two phases.
4Suction pipeline or shaft seal leaky. Retighten flange screw connections. Check shaft seal.
5Air in suction and pressure system. Open vent valve on pump pressure side until air has escaped.
Close valve again.
6Wrong fluid viscosity. Check that viscosity matches entries in acceptance test report.
In case of zero–pressure delivery of low–viscosity fluids, apply
1 to 2 bar to pump.
7 Pressure–relief valve leaking. Check pressure–relief valve for passage. If necessary, regrind
valve seat and/or exchange valve cone.
8Geodetic suction head too high. Check underpressure on suction side using connected
pressure/vacuum gauge. Increase fluid level in tank, lower
pump.
9Motor speed too low. Check speed and currentconsumption of motor. Checkvoltage
and frequency against motor rating plate.
10 Air separating time in operating tank too short. Provide better air separation in operating tank. Return lines
must emerge below oil level of tank.
11 Fluid level in tank too low. Fill tank to necessary fluid level.

16
VM 623.0004 GB/07.00 –Ident–Nr. 550 298
12 Flow rate in suction and pressure pipelines too
high. Flow rate in suction pipeline must not exceed max. 1 m/s, and in pressure pipeline max. 3 m/s.
13 Motor speed too high. Check speed and current consumption. Check voltage and
frequency against motor rating plate.
14 Delivery pressure too high. Setspecified delivery pressureviapressure–relief valve. Pump
outlet pressure must not be exceeded.
15 Foreign bodies in pump. Dismantle pump, remove foreign bodies and smooth damaged
points with oilstone.
Check suction filter and strainer.
16 Damaged ball bearing. Replace ball bearing.
17 Pressure spring fatigued.
Valve seat leaking.
Install new pressure spring.
Install new valve cone.
18 Pressure spring heavily pre–tensioned.
Valve cone stuck in valve housing.
a) Due to foreign body or
b) Operating temperature of plant substantially
higher than quoted on order.
Release pressure spring using adjusting screw, and reset to
required pressure.
Dismantle pressure–relief valve. Clean internal parts.
Consult factory.
19 Pressure spring not pre–tensioned, or
insufficiently pre–tensioned.
Valve seat leaking.
Turn adjusting screw to right until required operating pressure
is reached.
Rework or replace valve cone and valve housing.
20 Pressure–relief valve knocking. Check overpressure with pressure valve closed. Reset valve.
Opening pressure 10 % above operating pressure.

Á
ÁÁ
17
VM 623.0004 GB/07.00 –Ident–Nr. 550 298
9 Associated documentation
9.1 Sectional drawing, Pump sizes 20 –40
EMTEC...D8.6 –Pump with suction and delivery casing, and threaded pipe connection, with shaft seal
Part No. Denomination
–––––––––––––––––––––––––––––––––
1 Delivery casing
2 Rotor housing
3 Pump cover, drive side
4 Suction casing
9 Pump cover, non–drive side
12 ÀDriving spindle
13 ÀIdler spindle
20 Intermediate cover
21 Labyrinth ring
22 Labyrinth ring
23 ÁSpacer ring
24 Spacer ring
25 Thrust cover
26 ÀBalance bush
100 ÀGasket
–––––––––––––––––––––––––––––––––
Part No. Denomination
–––––––––––––––––––––––––––––––––
121 ÀO–ring
122 ÀO–ring
126 ÀO–ring
129 ÀO–ring
130 ÀO–ring
140 ÀJoint ring
186 ÀMechanical seal
200 Socket–head cap screw
201 Stud bolt
204 Socket–head cap screw
214 Screw plug
220 Hexagon nut
250 Hexagon nut
251 Hexagon nut
252 ÂHexagon nut
–––––––––––––––––––––––––––––––––
Part No. Denomination
–––––––––––––––––––––––––––––––––
270 Clamping sleeve
280 Rivet
290 Key
292 ÀGroove ball bearing
420 Screwed fitting
421 Pipe
422 Pipe
970 Name plate
980 ÁPlug
981 ÁPlug
ÀSpare parts/Replacement parts
Ânot existent with size 40
–––––––––––––––––––––––––––––––––
ÁRemove plugs before start–up

ÁÁ
Á
Á
Á
18
VM 623.0004 GB/07.00 –Ident–Nr. 550 298
9.2 Sectional drawing, Pump sizes 20 –40
EMTEC...DQ –Pump with suction and delivery casing, and threaded pipe connection, without shaft seal
Part No. Denomination
–––––––––––––––––––––––––––––––––
1 Delivery casing
2 Rotor housing
3 Pump cover, drive side
4 Suction casing
9 Pump cover, non–drive side
12 ÀDriving spindle
13 ÀIdler spindle
20 Intermediate cover
21 Labyrinth ring
22 Labyrinth ring
24 Spacer ring
25 Thrust cover
26 ÀBalance bush
100 ÀGasket
–––––––––––––––––––––––––––––––––
Part No. Denomination
–––––––––––––––––––––––––––––––––
121 ÀO–ring
122 ÀO–ring
126 ÀO–ring
129 ÀO–ring
130 ÀO–ring
140 ÀJoint ring
200 Socket–head cap screw
201 Stud bolt
204 Socket–head cap screw
214 Screw plug
220 Hexagon nut
250 Hexagon nut
251 Hexagon nut
270 Clamping sleeve
–––––––––––––––––––––––––––––––––
Part No. Denomination
–––––––––––––––––––––––––––––––––
280 Rivet
290 Key
292 ÀGroove ball bearing
420 Screwed fitting
422 Pipe
970 Name plate
980 ÁPlug
981 ÁPlug
ÀSpare parts/Replacement parts
–––––––––––––––––––––––––––––––––
ÁRemove plugs before start–up

19
VM 623.0004 GB/07.00 –Ident–Nr. 550 298
9.3 Explosion drawing, Pump sizes 20 –40

ÁÁ
Á
20
VM 623.0004 GB/07.00 –Ident–Nr. 550 298
9.4 Sectional drawing, Pump sizes 80 –660
EMTEC...D8.6 –Pump with suction and delivery casing, and threaded pipe connection, with shaft seal
Part No. Denomination
–––––––––––––––––––––––––––––––––
1 Delivery casing
2 Rotor housing
3 Pump cover, drive side
4 Suction casing
9 Pump cover, non–drive side
12 ÀDriving spindle
13 ÀIdler spindle
20 Intermediate cover
21 Labyrinth ring
22 Labyrinth ring
23 Spacer ring
24 Bottom ring
25 Thrust cover
26 ÀBalance bush
100 ÀGasket
–––––––––––––––––––––––––––––––––
Part No. Denomination
–––––––––––––––––––––––––––––––––
121 ÀO–ring
122 ÀO–ring
126 ÀO–ring
128 ÀO–ring
129 ÀO–ring
130 ÀO–ring
140 ÀJoint ring
186 ÀMechanical seal
200 Socket–head cap screw
201 Socket–head cap screw
203 Socket–head cap screw
204 Socket–head cap screw
205 Socket–head cap screw
214 Screw plug
250 Hexagon nut
–––––––––––––––––––––––––––––––––
Part No. Denomination
–––––––––––––––––––––––––––––––––
251 Hexagon nut
280 Rivet
290 Key
292 ÀGroove ball bearing
420 Screwed fitting
421 Pipe
422 Pipe
970 Name plate
980 ÁPlug
981 ÁPlug
ÀSpare parts/Replacement parts
–––––––––––––––––––––––––––––––––
ÁRemove plugs before start–up