Allweiler NT Series Installation instructions

Centrifugal Pump with
Volute Casing
Original Operating Manual NT series
Version BA-2021.04 en-US
161-295/E
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.
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
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 Operator’s obligations ....................... 8
2.2.3 Obligations of personnel ..................... 8
2.3 Specific hazards .............................. 8
2.3.1 Explosion-hazard area ....................... 8
2.3.2 Electric shock ................................. 9
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 Labels ......................................... 10
3.1.1 Type plate ..................................... 10
3.1.2 Digital nameplate ............................. 10
3.1.3 Pump type code .............................. 11
3.2 Layout ......................................... 12
3.3 Shaft seals .................................... 12
3.3.1 Mechanical seals ............................. 12
3.3.2 Stuffing box ................................... 12
3.4 Auxiliary systems ... .. . . . . . . . .. .. .. . . . . . .. .. .. 13
3.4.1 Sealing systems .. .. . .. .. .. .. .. . . . .. .. .. .. .. . . 13
4 Transport, storage and disposal .................. 14
4.1 Transport ...................................... 14
4.1.1 Unpacking and inspection on delivery . . . . . . 14
4.1.2 Lifting .......................................... 14
4.2 Treatment for storage ........................ 15
4.3 Storage ....................................... 15
4.4 Removing preservative ...................... 15
4.5 Disposal ....................................... 15
5 Setup and connection .............................. 16
5.1 Preparing the setup .......................... 16
5.1.1 Checking the ambient conditions .. .. . . . . . .. 16
5.1.2 Preparing the installation site ............... 16
5.1.3 Preparing the foundation and surface .. .. .. 16
5.1.4 Removing preservative ...................... 16
5.1.5 Installing the heat insulation (optional) . . . . . 16
5.2 Installation on a foundation .................. 17
5.2.1 Placing the pump unit on the
foundation .................................... 17
5.2.2 Fastening the pump unit ..................... 17
5.3 Installation without a foundation .. .. . . . . . . . . 18
5.4 Installing the motor ........................... 18
5.5 Planning the pipes ........................... 18
5.5.1 Specifying supports and flange
connections ................................... 18
5.5.2 Specifying nominal diameters .. .. . . .. .. . . .. . 18
5.5.3 Specifying pipe lengths ...................... 19
5.5.4 Optimizing changes in cross-section and
direction ...................................... 19
5.5.5 Discharging leaks ............................ 19
5.5.6 Providing safety and control devices
(recommended) .............................. 19
5.6 Connecting the pipes ........................ 19
5.6.1 Keeping the piping clean .................... 19
5.6.2 Installing auxiliary pipes (if available) . . . .. .. 19
5.6.3 Installing the suction pipe .................... 19
5.6.4 Installing the pressure pipe .................. 20
5.6.5 Inspection for stress-free pipe
connections ................................... 20
5.6.6 Checking the support foot for distortion (if
available) ..................................... 20
5.7 Electrical connection ......................... 20
5.7.1 Connecting the motor ........................ 20
5.7.2 Checking the sense of rotation .............. 20
5.8 Aligning the coupling precisely .............. 21
5.9 Aligning the motor ............................ 22
5.9.1 Aligning the motor with sets of shims . . . .. .. 22
5.9.2 Aligning the motor with adjusting
screws ........................................ 22
5.10 Installing the coupling guard ................ 22
6Operation ............................................ 23
6.1 Preparations for the initial start-up .. . . .. . . . . 23
6.1.1 Identifying the pump type .................... 23
6.1.2 Removing preservative ...................... 23
6.1.3 Lubricating the bearings ..................... 23
6.1.4 Preparing auxiliary systems (if
available) ..................................... 23
6.1.5 Filling and bleeding .......................... 23
6.2 Start-up ....................................... 24
6.2.1 Switching on .................................. 24
6.2.2 Switching off .................................. 24
6.3 Shutting down the pump ..................... 24
6.4 Start-up following a shutdown period ... . . . . 25
6.5 Operating the stand-by pump ............... 25
7 Maintenance ......................................... 26
7.1 Inspections ................................... 26
7.2 Maintenance .................................. 26
7.2.1 Antifriction bearings lubricated with
grease ......................................... 26
7.2.2 Mechanical seals ............................. 26
7.2.3 Stuffing box ................................... 26
7.2.4 Cleaning the pump ........................... 26
7.3 Dismounting .................................. 27
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Table of contents
7.3.1 Returning the pump to the manufac-
turer ........................................... 27
7.3.2 Preparations for dismounting ................ 27
7.4 Installing ...................................... 28
7.5 Ordering spare parts ......................... 28
8 Troubleshooting .................................... 29
9 Appendix ............................................. 32
9.1 Sectional drawing ............................ 32
9.1.1 Auxiliary connections ........................ 32
9.1.2 Part numbers and designations ............. 32
9.1.3 Sectional drawings ........................... 34
9.1.4 Seals .......................................... 41
9.1.5 Coupling guard ............................... 41
9.2 Technical specifications ...................... 42
9.2.1 Ambient conditions ........................... 42
9.2.2 Parameters for auxiliary systems .. . . . . . . . . . 42
9.2.3 Sound pressure level ........................ 42
9.2.4 Tightening torques ........................... 43
9.2.5 Cleaning agents .............................. 43
9.2.6 Lubricants ..................................... 43
9.2.7 Bearing bracket size ......................... 44
9.2.8 Height offset for motor alignment with
adjusting screw ............................... 45
9.2.9 Flange loads according to ISO 5199 .. . . .. . 46
9.3 Spare parts for two years of continuous
operation according to DIN 24296 . . . .. .. .. . 48
9.4 Declaration of harmlessness ................ 49
9.5 Declaration of conformity according to EC
Machine Directive ............................ 50
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Table of contents
List of figures
Fig. 1 Type plate (example) ........................ 10
Fig. 2 Digital nameplate, standard version
(example) ..................................... 10
Fig. 3 Digital nameplate, variant with optional RFID
transmitter (example) ........................ 10
Fig. 4 Pump type code (example) .................. 11
Fig. 5 NT layout ..................................... 12
Fig. 6 Single mechanical seal with quenching
(sketch) ....................................... 13
Fig. 7 Fastening lifting gear to pump unit . . . . . . .. . . 14
Fig. 8 Fastening the lifting gear to the pump . . . . . . 14
Fig. 9 Setting down the pump without an installed
support foot ................................... 14
Fig. 10 Installation with foundation .................. 17
Fig. 11 Checking for distortion ....................... 17
Fig. 12 Installation without a foundation .. . . . . .. .. . . 18
Fig. 13 Straight pipe lengths upstream
and downstream of the pump
(recommended) .............................. 19
Fig. 14 Checking the alignment of the
coupling ....................................... 21
Fig. 15 Checking for lateral and vertical
misalignment ................................. 21
Fig. 16 Checking for angular displacement . . . . . . . . . 21
Fig. 17 Aligning the motor with adjusting
screws ........................................ 22
Fig. 18 U…D – Unbalanced mechanical seal ... . . . 34
Fig. 19 U3…D – Unbalanced mechanical seal ... .. 35
Fig. 20 U3…D – Unbalanced mechanical seal ... .. 36
Fig. 21 U3…D – Unbalanced mechanical seal ... .. 37
Fig. 22 U3…D – Unbalanced mechanical seal ... .. 38
Fig. 23 U3…D – Unbalanced mechanical seal ... .. 39
Fig. 24 U3…D – Unbalanced mechanical seal ... .. 40
Fig. 25 U1C –Stuffingboxwithexternal
flushing ........................................ 41
Fig. 26 U3…D – Unbalanced mechanical seal ... .. 41
Fig. 27 U3.9D, U3.12D – Unbalanced mechanical
seal ............................................ 41
Fig. 28 U1B – Stuffing box with self-locking ........ 41
Fig. 29 Coupling guard on base plate versions .. . . . 41
Fig. 30 Empirical formulas for forces and
torques ........................................ 46
Fig. 31 Flange loads at the pump ................... 46
Fig. 32 Correction factor M and operating
temperature ................................... 47
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 ............................................. 13
Tab. 7 Treatment for storage ........................ 15
Tab. 8 Measures to be taken if the pump is shut
down .......................................... 24
Tab. 9 Measures depending on the behavior of the
pumped liquid ................................ 24
Tab. 10 Measures to be taken after prolonged
shutdown periods ............................ 25
Tab. 11 Measures for return .......................... 27
Tab. 12 Malfunction/number assignment ............ 29
Tab. 13 Troubleshooting list .......................... 31
Tab. 14 Connection designation abbreviations .. . . . . 32
Tab. 15 Designation of components according to part
numbers ...................................... 33
Tab. 16 Versions and details at bearing bracket
700 ............................................ 40
Tab. 17 Ambient conditions ........................... 42
Tab. 18 Operating parameters for sealing medium in
open flow system . .. .. . .. .. . . . . . . . .. ... .. .. . . . 42
Tab. 19 Sound pressure level ........................ 42
Tab. 20 Tightening torques ........................... 43
Tab. 21 Cleaning agents .............................. 43
Tab. 22 Grease types ................................. 43
Tab. 23 Minimum amounts for grease
lubrication ..................................... 43
Tab. 24 Bearing bracket size ......................... 44
Tab. 25 Height setting at the adjusting screw .. . . . . . 45
Tab. 26 Flange loads .................................. 47
Tab. 27 Spare parts for two years of continuous
operation ...................................... 48
Tab. 28 Declaration of harmlessness ............... 49
Tab. 29 Declaration of conformity according to EC
Machine Directive ............................ 50
4 NT series BA-2021.04 en-US 161-295/E

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 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,
Content of the declaration of conformity (→ 9.5 Declaration of
conformity according to EC Machine Directive, Page 50).
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 as seal barrier/buffer fluid or for quenching of shaft seals
Auxiliary systems Systems for operating the pump
Tab. 5 Technical terms and their meaning
6 NT series BA-2021.04 en-US 161-295/E

Safety
2Safety
The manufacturer does not accept any liability for damage
resulting from disregard of the entire documentation.
2.1 Intended use
• Only use the pump for pumping the agreed pumped media
(→ order data sheet).
• Adhere to the operating limits 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 fitting beyond the
agreed operating point.
• Avoid overheating:
– Do not operate the pump while the pressure-side fitting
is closed.
– Observe the minimum flow rate (→ order data sheet).
• Avoid damage to the motor:
– Do not open the pressure-side fitting 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.
• Pumps delivered without a motor must be assembled into
apumpunitaccordingtotheprovisionsofECMachine
Directive 2006/42/EC.
Prevention of likely misuse (examples)
• Note the operating limits of the pump with regard to 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, coupling or motor, stay within the agreed density
(→ order data sheet).
Lower densities are allowed. Adapt the auxiliary systems
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
Observe the following regulations before carrying out any
work.
2.2.1 Product safety
The pump has been constructed according to the latest tech-
nology and recognized technical safety rules. Nevertheless,
operation of the pump can still put the life and health of the
user or third parties at risk or damage the pump or other prop-
erty.
• Only operate the pump if it is in perfect technical condition
and only use it as intended, staying aware of safety and
risks, and in adherence to the instructions in this manual.
• Keep this manual and all other applicable documents com-
plete, legible and accessible to personnel at all times.
• Refrain from any procedures and actions that would pose
a risk to personnel or third parties.
• In the event of any safety-relevant malfunctions, shut down
the pump immediately and have the malfunction corrected
by appropriate personnel.
• In addition to the entire documentation for the product,
comply with statutory or other safety and accident-preven-
tion regulations and the applicable standards and guide-
lines in the country where the pump is operated.
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Safety
2.2.2 Operator’s obligations
Safety-conscious operation
• Only operate the pump if it is in perfect technical condition
and only use it as intended, staying aware of safety and
risks, and in adherence to the instructions in this manual.
• Ensure that the following safety aspects are observed and
monitored:
– 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 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.
• Make sure that trainee personnel only work on the pump
under 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
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.
• Use elastic 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
– Do not use them as a fixing 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.
• 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 before all assembly
and 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).
8 NT series BA-2021.04 en-US 161-295/E

Safety
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.
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.
• Keep a sufficient 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.
161-295/E BA-2021.04 en-US NT series 9

Layout and function
3 Layout and function
3.1 Labels
3.1.1 Type plate
ALLWEILER GmbH
Allweilerstraße 1, 78315 Radolfzell / Germany
Technical File No.:
EX9 09 45910 002
Kreiselpumpe
Typ: _________________________
Q = ____ m³/h NPSH = ____ Jahr
Ø = ___ mm
MEI >=
Eta = --.-
m
kg/dm³
mm²/s
H = ____ m
n = ____ 1/min
P = ____ kW
Nr. 12345678
____
____
12
11
15
14
13 3
4
5
1
2
10 87 6
9
II 2G Ex h IIC T4..T1 Gb
Fig. 1 Type plate (example)
1 Pump number
2 Year of manufacture
3 Impeller diameter
4 Minimal efficiency index (MEI)
5 Eta efficiency (—.- = not specified)
6 Pump NPSH value
7Density
8 Kinematic viscosity
9 Reference to ATEX additional instructions
10 Explosion protection mark
11 Power consumption
12 Motor speed
13 Differential head
14 Flow rate
15 Pump type code
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
10 NT series BA-2021.04 en-US 161-295/E

Layout and function
3.1.3 Pump type code
1
2
3
4
NT 2 / 32 – 200 / 01 180 U3D W10
5
6
7
8
Fig. 4 Pump type code (example)
1Series
2 Number of stages (only with two-stage pumps)
3 Outlet flange DN [mm]
4 Nominal impeller diameter [mm]
5 Hydraulic number
6 Actual impeller diameter [mm]
7 Shaft seal
8 Material key
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Layout and function
3.2 Layout
12 345
6
Fig. 5 NT layout
1Impeller
2 Volute casing
3 Limit for heat insulation
4 Bearing bracket
5Shaft
6 Shaft seal
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
3.3.2 Stuffing box
Thestuffingboxmustalwaysleak slightly to carry the fric-
tional heat away.
12 NT series BA-2021.04 en-US 161-295/E

Layout and function
3.4 Auxiliary systems
3.4.1 Sealing systems
Quenching
1 2 3
Fig. 6 Single mechanical seal with quenching
(sketch)
1Seal
2 Quench space
3 Quench medium connection
The pressure of the pumped liquid is higher than the pressure
of the sealing medium during quenching. The seal surfaces
are lubricated by the pumped liquid.
Application examples:
• Pumped liquids 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
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.
If the pump has a support foot, attach the support foot to
the pump.
For pumps without a support foot, use a shim plate on site.
Fig. 7 Fastening lifting gear to pump unit
Fig. 8 Fastening the lifting gear to the pump
Lift the pump/unit properly.
1
Fig. 9 Setting down the pump without an installed
support foot
1Base
Set down the pump properly.
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Transport, storage and disposal
4.2 Treatment for storage
Not necessary for stainless 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 corrosion protection agent.
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.
4.4 Removing preservative
Only necessary for pumps treated for storage.
WARNING
Risk of poisoning by preservatives and cleaning agents in
the foodstuffs and drinking water sector!
Only use cleaning agents which are compatible with the
pumped liquid (→ 9.2.5 Cleaning agents, Page 43).
Completely remove the 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 by using the wrong cleaning agents!
Ensure the cleaning agent does not corrode the seals.
1. Choose the cleaning agent according to the application.
(→ 9.2.5 Cleaning agents, Page 43).
2. Dispose of preservatives according to local regulations.
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-
tive pumped liquids to such an extent that cleaning will be
insufficient.
WARNING
Risk of poisoning and environmental damage by the
pumped liquid or oil!
Use protective equipment when carrying out any work on
the pump.
Prior to the disposal of the pump:
– Collect and dispose of any leaking pumped fluid or oil
in accordance with local regulations.
– Neutralize residues of pumped liquid in the pump.
– Removing the preservative (→ 4.4 Removing preser-
vative, Page 15).
Remove the 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 transportation locks until immediately
before installing the pump.
Do not remove any covers or transport and sealing covers
until immediately before connecting the pipes to the pump.
5.1 Preparing the setup
5.1.1 Checking the ambient conditions
Make sure the required ambient conditions are fulfilled
(→ 9.2.1 Ambient conditions, Page 42).
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 foundation and surface
Setup options:
– With concrete foundation
– With steel foundation frame
– Without foundation
Make sure the foundation and surface meet the following
conditions:
–Level
– Clean (no oil, dust or other impurities)
– Capable of bearing the weight of the pump unit and all
operating forces
– Ensure the pump is stable and cannot tip over
– With concrete foundation: standard concrete of
strength class B 25
5.1.4 Removing preservative
If the pump is to be put into operation immediately after
setup and connection: Remove the preservative prior to
installation (→ 4.4 Removing preservative, Page 15).
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 volute casing (→ Fig.
5 NT layout, Page 12).
Install the heat insulation properly.
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Setup and connection
5.2 Installation on a foundation
NOTE
Material damage due to distortion of the base plate!
Place the base plate on the foundation and secure it as
described in the following.
5.2.1 Placing the pump unit on the foundation
Implements, tools and materials:
– Foundation bolts (→ setup drawing)
– Steel washers
– Non-shrinking mortar grout
– Spirit level
1. Lifting the pump unit (→ 4.1 Transport, Page 14).
2. Attach the foundation bolts from below into the base plate
fixing holes.
Observe the manufacturer’s instructions when using adhe-
sive anchors.
3. Set the pump unit down on the foundation. When doing
so, sink the foundation bolts into the prepared anchoring
holes.
32 1 2
Fig. 10 Installation with foundation
4. Use steel washers to align the pump unit to the height and
system dimensions as described in the following:
– Place a steel washer (2) to the left and right-hand side
of each foundation bolt (1).
– If the distance between the anchoring holes is greater
than 750 mm, place additional steel washers (3) in the
middle, on each side of the base plate.
5. Make sure the steel washers lie flat against the base plate,
in full contact.
6. Use the integrated spirit level to check whether the pump is
level end to end and side to side with a maximum allowable
tilt of 1 mm/m.
7. Repeat the procedure until the base plate is correctly
aligned.
5.2.2 Fastening the pump unit
The damping behavior is improved by filling the base plate
with mortar grout.
1. Fill the anchoring holes with mortar grout.
2. When the mortar grout has set, screw down the base plate
at three points with the specified torque.
3. Before tightening the remaining bolts, compensate for any
unevenness in the surface using metal spacing shims next
to each bolt.
4. Check the pump unit for any distortion with a straightedge:
1
Fig. 11 Checking for distortion
– Measure in two planes at an angle of 90° on the cir-
cumference of the coupling.
– Check the light gap at the outer diameter using a
straightedge (1):
Position the straightedge across both halves of the
coupling.
If there is significant deviation, undo the fixing to the
base plate and correct the distortion by inserting more
shims.
– Fill the inside of the base plate with concrete, if
intended. Knock on the base plate to ensure that no
cavities are created in the process.
Couplings with a spacer piece (dismountable coupling) can
also be checked with a dial gauge.
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Setup and connection
5.3 Installation without a foundation
This is only permissible if the pump is intended for installa-
tion without a foundation (→ order data sheet).
Resources, tools and materials:
–Wrench
– Spirit level
1
1
1
1
2
4
5
3
Fig. 12 Installation without a foundation
1. Lifting the pump unit (→ 4.1.2 Lifting, Page 14).
2. Install four leveling feet (1) as shown.
– Do not forget the washer (3) under the base plate.
3. Set the pump aggregate down on the surface.
4. Use the leveling feet (1) to adjust the height of the base
plate as shown above:
– Use a wrench to hold the hexagon nut (4) steady on
the leveling foot (5).
– Loosen the hexagon nut (2).
– Adjust the height by turning the hexagon nut (4).
– Tighten the hexagon nut (2) (→ 9.2.4 Tightening
torques, Page 43).
– Use the integrated spirit level to check whether the
pump is level end to end and side to side with a maxi-
mum allowable tilt of 1 mm/m.
– Repeat the procedure until the base plate is correctly
aligned.
5.4 Installing the motor
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 shaft keys.
3. Without a mounting rig: remove the rubber buffers and heat
the coupling halves up to approximately 100 °C.
4. Slideonthepump-sideandmotor-sidecouplinghalves
until the shaft end is flush with the coupling hub. When
doing so, make sure the prescribed distance between the
coupling halves is maintained (→ Assembly instructions for
the coupling).
5. Tighten the grub screws on both coupling halves.
6. Use suitable metal shims at the motor to align the end of
the motor shaft to the end of the pump shaft.
7. Screw in the motor bolts, but do not tighten them yet
(→ 5.9 Aligning the motor, Page 22).
5.5 Planning the pipes
5.5.1 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 (→ 9.2.9 Flange loads
according to ISO 5199, Page 46).
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.
5.5.2 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 flange diameter.
– Recommended flow rate speed < 1 m/s
2. Make sure the nominal pressure pipe diameter is ≥ as pos-
sible to the nominal outlet flange diameter.
– Recommended flow rate speed < 3 m/s
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Setup and connection
5.5.3 Specifying pipe lengths
C
D
B
A
Fig. 13 Straight pipe lengths upstream and downstream
of the pump (recommended)
A > 5 x nominal suction pipe diameter
B Nominal suction pipe diameter
C Nominal pressure pipe diameter
D > 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.
5.5.4 Optimizing changes in cross-section and direction
1. Avoid bending radii of less than 1.5 times the nominal pipe
diameter.
2. Avoid abrupt changes of cross-section along the piping.
5.5.5 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.
5.5.6 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.
Avoiding reverse running
Install a non-return valve between the outlet flange and the
gate valve to ensure the medium does not flow back when
thepumpisswitchedoff.
Making provisions for isolating and shutting off pipes
For maintenance and repair work.
Provide shut-off devices in the suction and pressure pipes.
Allowing measurement 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.
5.6 Connecting the pipes
5.6.1 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 fittings prior to assembly.
2. Ensure no flange seals protrude inwards.
3. Remove any blank flanges, plugs, protective foils and/or
protective paint from the flanges.
5.6.2 Installing auxiliary pipes (if available)
Observe the manufacturers’ specifications for any auxiliary
operating systems which are present.
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.
5.6.3 Installing the suction pipe
1. Remove the transport and sealing covers from the pump.
2. To avoid air pockets: run the pipes with a continuous slope
up to the pump.
3. Ensure no seals protrude inwards.
4. For suction operation: install a foot valve in the suction pipe
to prevent the pump and suction pipe from running empty
during downtimes.
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Setup and connection
5.6.4 Installing the pressure pipe
1. Remove the transport and sealing covers from the pump.
2. Install the pressure pipe.
3. Ensure no seals protrude inwards.
5.6.5 Inspection for stress-free pipe connections
Piping installed and cooled down
NOTE
Material damage due to distorted pump casing
Ensure that all pipes are stress relieved when connected
to the pump.
1. Disconnect the pipe connecting flanges from the pump.
2. Check whether the pipes can be moved freely in all direc-
tions within the expected range of expansion:
– Nominal diameter < 150 mm : by hand
– Nominal diameter > 150 mm : with a small lever
3. Make sure the flange surfaces are parallel.
4. Reconnect the pipe connecting flanges to the pump.
5.6.6 Checking the support foot for distortion
(if available)
1. Loosen the bolts connecting the support foot to the base
plate.
2. If the support foot moves, compensate for distortion:
– Lateral shift: by means of slotted holes
– Vertical shift: by means of metal shims
3. Screw support foot back onto base plate. Make sure that
the bearing bracket is not distorted.
5.7 Electrical connection
DANGER
Risk of death due to electric shock!
Have all electrical work carried out by qualified electricians
only.
5.7.1 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.
5.7.2 Checking the sense of rotation
DANGER
Risk of death due to rotating parts!
Secure the shaft key from being thrown out when checking
the sense of rotation.
NOTE
Material damage caused by dry running or incorrect sense
of rotation!
Uncouple the motor from the pump.
1. Switch the motor on and immediately off again.
2. Check whether the motor’s sense of rotation is the same
as that of the arrow on the pump.
3. If the sense of rotation is different: swap two phases.
4. Couple the motor to the pump again.
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