Allweiler NIT Series Installation instructions

Centrifugal Pump with
Volute Casing
Original Operating Manual NIT series
Version BA-2017.03 en-US
ID-No. 550 154
160-282/0
ALLWEILER GmbH
Postfach 1140
Allweilerstr. 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.
Save 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
1.4 Technical terms ............................... 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 . ..... 8
2.2.3 Obligations of personnel ..................... 8
2.3 Specific hazards .............................. 8
2.3.1 Explosion hazard area ....................... 8
2.3.2 Hazardous pumped media .................. 8
3 Layout and function ................................ 9
3.1 Labels ......................................... 9
3.1.1 Type plate ..................................... 9
3.1.2 ATEX plate .................................... 9
3.1.3 Pump type code .............................. 9
3.2 Layout ......................................... 10
3.3 Shaft seals .................................... 11
3.3.1 Mechanical seals ............................. 11
3.4 Auxiliary systems ... .. .. . . . . . .. .. . . . .. . . .. .. . . 11
3.4.1 Sealing systems . . . . .. .. . . .. . . . .. .. .. .. . . . .. .. 11
4 Transport, storage and disposal .................. 12
4.1 Transport ...................................... 12
4.1.1 Unpacking and inspection on delivery . . . . . . 12
4.1.2 Lifting .......................................... 12
4.2 Preservation .................................. 12
4.3 Storage ....................................... 12
4.4 Removing the preservative .................. 13
4.5 Disposal ....................................... 13
5 Setup and connection .............................. 14
5.1 Preparing the setup .......................... 14
5.1.1 Checking the ambient conditions .. . . . .. . . . . 14
5.1.2 Preparing the installation site ............... 14
5.1.3 Removing the preservative .................. 14
5.1.4 Installing the heat insulation (optional) . . .. . 14
5.2 Planning the pipes ........................... 15
5.2.1 Specifying supports and flange
connections ................................... 15
5.2.2 Specifying nominal diameters .. .. . . . . . .. .. . . 15
5.2.3 Specifying pipe lengths ...................... 15
5.2.4 Optimizing cross-section and direction
changes ....................................... 15
5.2.5 Discharging leaks ............................ 15
5.2.6 Providing safety and control devices
(recommended) .............................. 15
5.3 Installing in the pipe .......................... 16
5.3.1 Keeping the piping clean .................... 16
5.3.2 Install pump aggregate ...................... 16
5.3.3 Installing auxiliary pipes (if available) . . . .. . . 16
5.4 Installing the motor ........................... 17
5.5 Electrical connection ......................... 18
5.5.1 Connecting the motor ........................ 18
5.5.2 Checking the direction of rotation . . .. . . . .. . . 18
5.6 Installing the coupling guard ................ 18
5.7 Performing the hydrostatic test .............. 18
6Operation ............................................ 19
6.1 Preparations for the initial start-up .. . . . .. . . . 19
6.1.1 Identifying the pump type .................... 19
6.1.2 Removing the preservative .................. 19
6.1.3 Preparing auxiliary systems (if
available) ..................................... 19
6.1.4 Filling and bleeding .......................... 19
6.1.5 Checking the direction of rotation . . .. . . . .. . . 20
6.2 Start-up ....................................... 20
6.2.1 Switching on .................................. 20
6.2.2 Switching off .................................. 21
6.3 Shutting down ................................ 21
6.4 Start-up following a shutdown period ... .. .. 22
6.5 Operating the stand-by pump ............... 22
7 Maintenance ......................................... 23
7.1 Inspections ................................... 23
7.2 Maintenance .................................. 23
7.2.1 Antifriction bearing ........................... 23
7.2.2 Mechanical seals ............................. 23
7.2.3 Sealing medium .............................. 24
7.2.4 Cleaning the pump ........................... 24
7.3 Dismounting .................................. 24
7.3.1 Returning the pump to the manufac-
turer ........................................... 25
7.3.2 Preparations for dismounting ................ 25
7.3.3 Removal of the flanged motor ............... 25
7.4 Installing ...................................... 26
7.4.1 Installation of the pump ...................... 26
7.4.2 Installation of the flanged motor ............. 26
7.5 Ordering spare parts ......................... 27
8 Troubleshooting .................................... 28
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 ........................... 33
9.2 Technical specifications ...................... 36
9.2.1 Stub shaft diameter at the shaft seal ... .. . . 36
9.2.2 Ambient conditions ........................... 36
9.2.3 Parameters for auxiliary systems . . .. . . . . . .. 36
9.2.4 Sound pressure levels ....................... 36
9.2.5 Tightening torques ........................... 37
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Table of contents
9.2.6 Cleaning agents .............................. 37
9.2.7 Flange loads .................................. 38
9.3 Spare parts for two years of continuous
operation according to DIN 24296 . . . . . . .. .. 39
9.4 Declaration of harmlessness ................ 40
9.5 Declaration of conformity according to EC
Machine Directives ........................... 41
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Table of contents
List of figures
Fig. 1 Type plate (example) ........................ 9
Fig. 2 ATEX plate (example) ........................ 9
Fig. 3 Pump type code (example) .................. 9
Fig. 4 Layout ......................................... 10
Fig. 5 Single mechanical seal with quenching
(sketch) ....................................... 11
Fig. 6 Fastening the lifting gear to the pump
aggregate ..................................... 12
Fig. 7 Straight pipe lengths upstream
and downstream of the pump
(recommended) .............................. 15
Fig. 8 Widening the stub shaft ...................... 17
Fig. 9 Motor assembly .............................. 17
Fig. 10 Widening the stub shaft ...................... 25
Fig. 11 Widening the stub shaft ...................... 26
Fig. 12 Motor assembly .............................. 27
Fig. 13 U5A - Unbalanced mechanical seal, with
safety stuffing box ............................ 33
Fig. 14 Fastening of the bearing housing cover and
fan casing ..................................... 34
Fig.15 Versionwithintermediatering(sizes40-250
and 50-250) ................................... 34
Fig. 16 Housing cover version (sizes 2/40-250 and
2/50-250) ..................................... 34
Fig. 17 Attachment of the guard sheet to the motor
bell housing ................................... 34
Fig. 18 Information plate (972.01), assignment of
connections ................................... 34
Fig. 19 Version with intermediate ring, sizes
40-250/01 and 50-250/01 .................... 34
Fig. 20 Two-stage sizes, non-cooled, unbalanced
mechanical seal U5A, with safety stuffing
box ............................................ 35
Fig. 21 Quenching seal housing ..................... 35
Fig. 22 Flange loads at the pump ................... 38
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 Technical terms and their meaning .. .. .. . .. 6
Tab. 6 Quenching - variants and characteris-
tics ............................................. 11
Tab. 7 Treatment for storage ........................ 12
Tab. 8 Measures to be taken if the pump is shut
down .......................................... 21
Tab. 9 Measures depending on the behavior of the
pumped medium ............................. 21
Tab. 10 Measures to be taken after prolonged
shutdown periods ............................ 22
Tab. 11 Measures for return .......................... 25
Tab. 12 Fault number assignment ................... 28
Tab. 13 Troubleshooting list .......................... 30
Tab. 14 Abbreviations of the connection
designations .................................. 31
Tab. 15 Designations of components according to
part numbers ................................. 32
Tab. 16 Assignment of the pump size to the stub
shaft diameter ................................ 36
Tab. 17 Ambient conditions ........................... 36
Tab. 18 Operating parameters for sealing medium in
open flow system . .. .. . . . . . . . .. .. .. . .. .. .. .. .. 36
Tab. 19 Sound pressure levels ....................... 36
Tab. 20 Tightening torques ........................... 37
Tab. 21 Cleaning agents .............................. 37
Tab. 22 Maximum flange loads ....................... 38
Tab. 23 Spare parts for two years of continuous
operation ...................................... 39
Tab. 24 Declaration of harmlessness ............... 40
Tab. 25 Declaration of conformity according to EC
machine directives ........................... 41
4 NIT series BA-2017.03 en-US 160-282/0 – 550 154

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
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
Spare parts list Ordering spare parts
Declaration of conformity Conformity with standards
Contents of the declaration of conformity (→9.5 Declaration of
conformity according to EC Machine Directives, Page 41).
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 disregard
DANGER Immediate acute risk Death, serious bodily harm
Potentially 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
1.4 Technical terms
Term Meaning
Sealing medium Medium for blocking or quenching shaft seals
Auxiliary systems Systems for operating the pump
Tab. 5 Technical terms and their meaning
6 NIT series BA-2017.03 en-US 160-282/0 – 550 154

Safety
2Safety
The manufacturer does not accept any liability caused by
disregarding 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 and size-dependent mini-
mum flow rate.
• Avoid dry running:
Initial damage, such as destruction of the mechanical seal
and plastic parts, will occur within only a few seconds.
– 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.
– Do not open the pressure-side armature beyond the
agreed operating point.
• Avoid overheating:
– Do not operate the pump while the pressure-side arma-
ture is closed.
– Observe the minimum flow rate (→order data sheet).
• Avoid damage to the motor:
– Do not open the pressure-side armature beyond the
agreed operating point.
– 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 concerning temper-
ature, pressure, flow rate and motor speed (→order data
sheet).
• The power consumed by the pump increases with increas-
ing density of the pumped liquid. To avoid overloading the
pump or motor, stay within the agreed density (→order
data sheet).
Lower densities are permissible. Adapt the auxiliary sys-
tems accordingly.
• When pumping liquids containing solids, ensure the limits
for the proportion of solids and the grain size are main-
tained (→order data sheet, technical description).
• When using auxiliary systems, ensure there is a continuous
supply of the appropriate operating medium.
• Pumps used with water as the pumped liquid must not be
used for foodstuffs or drinking water. Use of the pump for
foodstuffs or drinking water must be specified in the order
data sheet.
• Only select the setup type according to this operating man-
ual. 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
Take note of 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 involve risks to life and health of the
user or third parties and risk of damage to the pump and other
property.
• 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
expose personnel or third parties to any risk.
• In the event of any safety-relevant faults, shut down the
pump immediately and have the fault corrected by appro-
priate 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.
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Safety
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, 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:
– Adherence to 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.
• Ensure that all work is carried out by specialist technicians
only:
– Fitting, repair and maintenance work
– Work on the electrical system
• Make sure 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: safety guarding pro-
vided by the customer
– For possible build up of electrostatic charge: ensure
appropriate 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.
2.2.3 Obligations of personnel
• All directions given on the pump must be followed (and kept
legible), e.g. the arrow indicating the direction 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 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 keep it locked
inthatstatewhencarryingoutanyfitting 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 media
• Follow the safety regulations for handling hazardous sub-
stances when pumping hazardous (e.g. hot, flammable,
poisonous or potentially harmful) media.
• Use personal 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 Type plate
11
10
13
12 4
5
6
1
2
3
98 7
Fig. 1 Type plate (example)
1 Pump number
2 Pumptypecode
3 Year of manufacture
4 Impeller diameter
5 Minimal efficiency index (MEI)
6Etaefficiency (—.- = not specified)
7 Pump NPSH value
8Density
9 Kinematic viscosity
10 Motor speed
11 Power consumption
12 Differential head
13 Flow rate
3.1.2 ATEX plate
Technical File No.:
EX9 03 09 45910 002
II 2 G c b Tx
1
2
Fig. 2 ATEX plate (example)
1 Explosion protection mark
2 Reference to ATEX additional instructions
3.1.3 Pump type code
1
2
3
4
NIT 40 – 200 / 01 / 180 U3D – W3 –38 / 300
5
6
7
8
9
Fig. 3 Pump type code (example)
1Series
2 Size (standard nominal diameter)
3 Nominal impeller diameter
4 Hydraulic number
5 Actual impeller diameter [mm]
6 Shaft seal
7 Material key
8 Stub shaft bore hole diameter [mm]
9 Outer diameter of motor bell housing or intermediate
ring or flange size of electric motor
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Layout and function
3.2 Layout
1
2
3
4
5
6
7
8
Fig. 4 Layout
1 Motor with fixedbearingatdriveend
2 Motor bell housing
3 Stub shaft
4 Limit for heat insulation
5Impeller
6 Volute casing
7 Shaft seal
8 Guard sheet
10 NIT series BA-2017.03 en-US 160-282/0 – 550 154

Layout and function
3.3 Shaft seals
Only one of the following shaft seals can be used.
3.3.1 Mechanical seals
Mechanical seals have functional leaks.
• Single mechanical seal
• Single mechanical seal with quenching and upstream
safety stuffing box
3.4 Auxiliary systems
3.4.1 Sealing systems
Only one of the following sealing systems can be used.
Quenching
123
Fig. 5 Single mechanical seal with quenching
(sketch)
1 Pumped liquid
2 Single mechanical seal
3 Sealing medium (unpressurized)
The pressure of the pumped medium is higher than the pres-
sure of the sealing medium during quenching. The seal sur-
faces are lubricated by the pumped medium.
Application examples:
• Pumped media that can crystallize in the atmosphere and
thus cause damage to the seal in the long-term
• Prevention of offensive odors
• Cooling of seals
Variant Characteristics of the
sealing medium
Open flow system • Supplied and drained
continuously
• Unpressurized
Closed flow system • Circulates in a closed
circuit
• Unpressurized
Tab. 6 Quenching - variants and characteristics
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Transport, storage and disposal
4 Transport, storage and disposal
4.1 Transport
For weight specifications (→documents for the particular
order).
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.
Fasten the lifting gear as shown in the following illustra-
tions.
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.
Set the load down on a level surface.
Lift the pump/unit properly.
Fig. 6 Fastening the lifting gear to the pump aggregate
4.2 Preservation
Not necessary for non-rusting materials.
Contact the manufacturer for recommendations regarding
preservatives.
NOTE
Material damage due to inappropriate treatment for stor-
age!
Treat the pump properly, inside and outside, for storage.
Preserving pump (observe the processing specifications of
the manufacturers)
Duration
[months]
Measures
Up to 6 All bare metal parts should be treated,
inside and outside.
6–12 All bare metal parts should be treated,
inside and outside.
Shrink-wrap the pump in plastic film.
12 – 24 All bare metal parts should be treated,
inside and outside.
Shrink-wrap the pump in plastic film.
Use VCI anticorrosive.
Tab. 7 Treatment for storage
4.3 Storage
NOTE
Material damage due to inappropriate storage!
Treat and store the pump properly.
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
3. Turn the shaft once a month.
4. Make sure the shaft and bearing change their rotational
position in the process.
5. Every 6 months:
– Renew the preservative if necessary.
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Transport, storage and disposal
4.4 Removing the preservative
Only necessary for pumps treated with preservative
WARNING
Risk of poisoning from preservatives and cleaning agents
in the foodstuffs and drinking water sector!
Only use cleaning agents which are compatible with the
pumped liquid (→9.2.6 Cleaning agents, Page 37).
Completely remove all preservative.
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.
(→9.2.6 Cleaning agents, Page 37).
2. Dispose of cleaning agents in accordance with local regu-
lations.
3. 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.
4.5 Disposal
Plastic parts can be contaminated by poisonous or radioac-
tivepumpedmediatosuchanextentthatcleaningisinsuf-
ficient.
WARNING
Risk of poisoning and environmental damage by the
pumped medium or oil!
Use personal protective equipment when carrying out any
work on the pump.
Prior to the disposal of the pump:
– Catch and dispose of any escaping pumped medium
or oil in accordance with local regulations.
– Neutralize residues of pumped medium in the pump.
– Remove any preservative (→4.4 Removing the
preservative, Page 13).
Remove any plastic parts and dispose of them in accor-
dance 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 transport seals until immediately before
settingupthepump.
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 Checking the ambient conditions
Make sure the required ambient conditions are fulfilled
(→9.2.2 Ambient conditions, Page 36).
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 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 Removing the preservative
If the pump is to be put into operation immediately after
setup and connection:
– remove the preservative prior to setup
(→4.4 Removing the preservative, Page 13).
5.1.4 Installing the heat insulation (optional)
Only necessary to maintain the temperature of the pumped
medium
NOTE
Material damage on the bearing or shaft seal due to over-
heating!
Only install the heat insulation on the volute casing
(→Figure Layout, Page 10).
Install the heat insulation properly.
14 NIT series BA-2017.03 en-US 160-282/0 – 550 154

Setup and connection
5.2 Planning the pipes
5.2.1 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 limits (→9.2.7 Flange
loads, Page 38).
1. Calculate the pipe forces, taking every possible operating
condition into account:
–Cold/warm
– Empty/full
– Unpressurized/pressurized
– Shift in position of flanges
2. Ensure the pipe supports have permanent low-friction
properties and do not seize up due to corrosion.
5.2.2 Specifying nominal diameters
Keep the flow resistance in the pipes as low as possible.
1. Where possible, make sure the nominal suction pipe diam-
eter is ≥as possible to the nominal suction flange diameter.
– Recommended flowratespeed<1m/s
2. Make sure the nominal pressure pipe diameter is ≥as pos-
sible to the nominal pressure flange diameter.
– Recommended flowratespeed<3m/s
5.2.3 Specifying pipe lengths
A
B
Fig. 7 Straight pipe lengths upstream and downstream
of the pump (recommended)
A > 5 x nominal suction pipe diameter
B > 5 x nominal pressure 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.
5.2.4 Optimizing cross-section and direction changes
1. Avoid radii of curvature of less than 1.5 times the nominal
pipe diameter.
2. Avoid abrupt changes of cross-section along the piping.
5.2.5 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.
5.2.6 Providing safety and control devices
(recommended)
Avoid impurities
1. Integrate a filter in the suction pipe.
2. To monitor impurities, install a differential pressure gauge
with a contact manometer.
Avoid reverse running
Install a non-return valve between the pressure flange and
the gate valve to ensure the medium does not flow back
whenthepumpisswitchedoff.
Enabling venting
Provide a vent valve on the highest pressure line position.
Avoid running empty
For suction operation: install a foot valve in the suction pipe
to prevent the pump and suction pipe from running empty
during downtimes.
Make provisions for isolating and shutting off the pipes
For maintenance and repair work.
Provide shut-off devices in the suction and pressure pipes.
Allow measurements of the operating conditions
1. Provide manometers for pressure measurements in the
suction and pressure pipes.
2. Provide load monitors (overload and underload) on the
motor side.
3. Provide for pump-side temperature measurements.
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Setup and connection
5.3 Installing in the pipe
5.3.1 Keeping the piping clean
NOTE
Material damage due to impurities in the pump!
Make sure no impurities can enter the pump.
1. Clean all piping parts and armatures prior to assembly.
2. Ensure no flange seals protrude inwards.
3. Remove any blind flanges, plugs, protective foils and/or
protective paint from flanges.
5.3.2 Install pump aggregate
NOTE
Material damage due to excessive forces!
Makesurethepipeisabletobeartheweightofthepump
aggregate and all operating forces which occur.
Make sure that the distance and alignment of the pipe
flanges comply with the pump dimensions (→setup draw-
ing).
1. Remove the transport and sealing covers from the pump.
2. Lift the pump aggregate (→4.1 Transport, Page 12).
3. Raise the pump aggregate between the pipe ends.
– Observe the pumping direction of the pump.
– Horizontal installation: Motor at top.
– Vertical installation: Connections (A5, E6) at top.
4. Screw the suction flange and discharge flange to the pipe.
– Maintain the prescribed tightening torques
(→9.2.5 Tightening torques, Page 37).
5.3.3 Installing auxiliary pipes (if available)
Follow the manufacturers' specifications for any available
auxiliary systems.
1. Connect the auxiliary pipes to the auxiliary connections so
that they are stress-free and do not leak (→setup drawing).
2. To avoid air pockets, run the pipes with a continuous slope
up to the pump.
3. On versions with quenching:
– Feed the quenching egress (QO2) into a closed con-
tainer.
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Setup and connection
5.4 Installing the motor
Only necessary if the pump aggregate is assembled on site
WARNING
Risk of injury due to overturning motor!
Secure the motor to prevent overturning before working on
the stub shaft.
NOTE
Damage due to incorrect installation!
Ensure that no excessive axial forces are applied to the
pump shaft.
Ensure that the stub shaft rests flush against the collar of
the motor shaft.
Stub shaft, free from oil and grease
The shaft key is not required for installation up to a stub
shaft bore hole diameter of 55 mm.
Stub shaft bore hole diameter (→3.1.3 Pump type code,
Page 9).
4
Fig. 8 Widening the stub shaft
1 Socket head cap screw
2 Stub shaft
3 Shaft key groove of motor shaft
4 Shaft key (from stub shaft bore hole diameter 60 mm)
1. Observe the following during installation:
– Adhere to the specified tightening torques
(→9.2.5 Tightening torques, Page 37).
2. Remove the retaining clamp for the stub shaft from the
motor bell housing (341.01):
– Undo the bolts/nuts (901.10) for this purpose
(→9.1 Sectional drawings, Page 31).
3. Undo the hexagon head bolts (901.07) and remove the
washers (554.07).
4. Remove one half of the guard sheet (686.01) from the
motor bell housing (341.01).
The Allen key required to undo the socket head cap screw
(914.14) is inserted in one of the two cast-in recesses in
the motor bell housing.
5. Undo the socket head cap screw (914.14) on the stub shaft
(220.xx) and unscrew it completely (→9.1 Sectional draw-
ings, Page 31).
Tighten the jack screw with a screwdriver without applying
any excessive force.
6. Widening the stub shaft (220.xx):
– Screw the M10 x 40 or M12 x 40 jack screw (not
included in the scope of delivery) into the stub shaft.
7. From stub shaft bore hole diameter 60 mm: insert the shaft
key.
8. Turn the motor shaft so that the slot of the stub shaft is
opposite the shaft key groove of the motor shaft.
0 mm
Fig. 9 Motor assembly
9. Carefully, slide on the motor until the stub shaft rests flush
against the collar of the motor shaft.
– Ensure that no excessive axial forces are applied to the
pump shaft.
10. Screw in the motor bolts and tighten them.
– Ensure that the stub shaft continues resting flush
against the collar of the motor shaft.
11. Undo and unscrew the jack screw. Screw in the socket
head cap screw (914.14) and tighten it with a torque wrench
(→9.2.5 Tightening torques, Page 37).
12. Install the safety equipment:
– Guard sheet for the motor bell housing
13. Install the auxiliary devices:
– Manometer lines and holdings on the pump
– Auxiliary piping
14. Turn the stub shaft by hand:
– Ensure the stub shaft can be turned easily without pres-
sure points.
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Setup and connection
5.5 Electrical connection
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
inthatstatewhencarryingoutanyfitting or maintenance
work.
5.5.1 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.
5.5.2 Checking the direction of rotation
Only possible when putting the pump into service
(→6.1 Preparations for the initial start-up, Page 19).
5.6 Installing the coupling guard
Flanged drive
1. Install the coupling guard (2 x 685.01) on the bell housing.
5.7 Performing the hydrostatic test
Only required if the entire system is subject to a hydrostatic
test.
NOTE
Damage to equipment through bursting of the pump cas-
ing
The test pressure may not exceed the maximum permissi-
ble pump pressure (→order data sheet).
1. Carry out the hydrostatic test with heat-transfer oil.
2. Ensure that the test pressure does not exceed the maxi-
mum permissible pump pressure.
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Operation
6 Operation
For pumps in explosion hazard areas (→ATEX additional
instructions).
6.1 Preparations for the initial start-up
6.1.1 Identifying the pump type
Identify the pump type (→order data sheet).
The pump types vary e.g. with regard to the shaft seal,
auxiliary systems.
6.1.2 Removing the preservative
Only necessary for pumps treated with preservative
(→4.4 Removing the preservative, Page 13).
6.1.3 Preparing auxiliary systems (if available)
The manufacturer does not accept any liability for damage
arising from the installation or use of a third-party or unap-
proved auxiliary system.
Sealing systems
1. Verify that the sealing medium is suitable to mix (i.e. com-
patible) with the pumped medium.
2. Identify the sealing system:
–(→order data sheet)
–(→3.4.1 Sealing systems, Page 11).
3. Install the sealing system (→manufacturer's specifica-
tions).
4. Make sure the parameters required for the installed sealing
system are met (→9.2.3 Parameters for auxiliary systems,
Page 36).
5. Ensure that the permissible container pressure is not
exceeded on blocking pressure systems (→manufac-
turer's specifications).
6.1.4 Filling and bleeding
Auxiliary systems ready for operation
WARNING
Risk of injury and poisoning due to hazardous pumped
media!
Safely collect any leaking pumped medium and dispose
of it in accordance with environmental rules and require-
ments.
NOTE
Material damage caused by dry running!
Make sure the pump is filled properly.
Filling and venting the pump
1. Fill the pump and the suction pipe with pumped medium.
2. Open the suction-side armature.
3. Open the pressure-side armature.
4. If present: open the auxiliary systems and check the flow
rate.
5. Verify that no pipe connections are leaking.
Filling and venting the bearing housing
(horizontal version)
1. Remove the screw plug A6/E6.
2. Fill slowly with pumped liquid up to the bottom edge of the
filling hole.
– Ensure that the air can escape from the bearing hous-
ing.
3. Screw in and tighten the screw plug A6/E6.
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Operation
Filling and venting the bearing housing (vertical version)
1. Remove the screw plugs A5 and E6.
2. Fill slowly with pumped liquid in filling hole A5 until liquid
escapes from vent opening E6.
3. Screw in and tighten screw plugs A5 and E6.
6.1.5 Checking the direction of rotation
DANGER
Risk of death due to rotating parts!
Use personal protective equipment when carrying out any
work on the pump.
Keep an adequate distance to rotating parts.
NOTE
Material damage due to incorrect direction of rotation!
Make sure the direction of rotation of the motor corre-
sponds to the arrow indicating the direction of rotation on
the motor bell housing.
1. Switch the motor on and immediately off again.
2. Check whether the direction of rotation of the motor corre-
sponds to the arrow indicating the direction of rotation on
the pump.
3. If the direction of rotation is different: swap two phases
(→5.5 Electrical connection, Page 18).
6.2 Start-up
6.2.1 Switching on
Pump aggregate set up and connected properly
All connections stress-free and sealed
Any available auxiliary systems are ready for operation
All safety equipment installed and tested for functionality
Pump prepared, filled and bled properly
DANGER
Risk of injury due to running pump!
Do not touch the running pump.
Ensure that the coupling guard is attached.
Do not carry out any work on the running pump.
Allow the pump to cool down completely before starting any
work.
DANGER
Risk of injury and poisoning caused by pumped medium
spraying out!
Use personal protective equipment when carrying out any
work on the pump.
NOTE
Material damage caused by dry running!
Make sure the pump is filled properly.
NOTE
Risk of cavitation when throttling down the suction flow
rate!
Fully open the suction-side armature and do not use it to
adjust the flow rate.
Do not open the pressure-side armature beyond the oper-
ating point.
NOTE
Material damage caused by overheating!
Do not operate the pump for long periods with the pressure-
side fitting closed.
Observe the minimum flow rate (→order data sheet).
1. Open the suction-side armature.
2. Close the pressure-side armature.
3. Switch on the motor and check it for smooth running.
4. Once the motor has reached its nominal speed, open the
pressure-side armature slowly until the operating point is
reached.
5. For pumps with hot pumped liquids, make sure any tem-
perature changes do not exceed 5 K/min.
20 NIT series BA-2017.03 en-US 160-282/0 – 550 154