ETNA EA Series User manual

End Suction Pumps
Installation, Operation And Maintenance Manual
EA EAR
EAS

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1. INTRODUCTION AND SAFETY
1.1 Introduction
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product
can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
1.1.1 Inexperienced Users
WARNING:
This product is intended to be operated by qualified personnel only.
Be aware of the following precautions:
• This product is not to be used by anyone with physical or mental disabilities, or anyone without
the relevant experience and knowledge, unless they have received instructions on using the
equipment and on the associated risks or are supervised by a responsible person.
• Children must be supervised to ensure that they do not play on or around the product.
1.2 Safety Terminology and Symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent these
hazards:
• Personal accidents and health problems
• Damage to the product and its surroundings
• Product malfunction
Hazard levels
Hazard level Indication
DANGER: A hazardous situation which, if not avoided, will result in death or
serious injury
WARNING: A hazardous situation which, if not avoided, could result in death or
serious injury
CAUTION: A hazardous situation which, if not avoided, could result in minor or
moderate injury
NOTICE: Notices are used when there is a risk of equipment damage or
decreased performance, but not personal injury.

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Special symbols
Some hazard categories have specific symbols, as shown in the following table.
Hot surface hazard
Hot surface hazards are indicated by a specific symbol that replaces the typical hazard level
symbols:
CAUTION:
Description of user and installer symbols
Instructions
The instructions and warnings that are provided in this manual concern the standard version, as
described in the sales document. Special version Pumps may be supplied with supplementary
instruction leaflets. Refer to sales contract for any modifications or special version
characteristics. For instructions, situations, or events that is not considered in this manual or the
sales document, contact the nearest Service Center.
1.3 Disposal of Packaging and Product
Observe the local regulations and codes in force regarding sorted waste disposal.
1.4 Warranty
For information about warranty, see the sales contract.
1.5 Spare Parts
WARNING:
Only use original spare parts to replace any worn or faulty components. The use of unsuitable
spare parts may cause malfunctions, damage, and injuries as well as void the guarantee.
CAUTION:
Always specify the exact product type and part number when requesting technical information
or spare parts from the sales department.
For more information about the product’s spare parts, visit sales network’s website.
Electrical hazard
Electrical
Hazard:
CAUTION:
Magnetic fields hazard
Specific information for personnel in charge of installing the product
in the system (plumbing and/or electrical aspects) or in charge of
maintenance.
Specific information for users of the product.

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2. TRANSPORTATION AND STORAGE
2.1 Inspect the Delivery
1. Check the outside of the package for evident signs of damage.
2. Notify our distributor within eight days of the delivery date, if the product bears visible signs
of damage.
Unpack the unit
1. Follow applicable step:
• If the unit is packed in a carton, then remove the staples and open the carton.
• If the unit is packed in a wooden crate, then open the cover while paying attention to the
nails and straps.
2. Remove the securing screws or the straps from the wooden base.
2.1.1 Inspect the Unit
1. Remove packing materials from the product. Dispose of all packing materials in accordance
with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps. For your personal
safety, be careful when you handle nails and straps.
4. Contact the local sales representative if there is any issue
2.2 Transportation Guidelines
Precautions
WARNING:
• Observe accident prevention regulations in force.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and
wear steel-toed shoes at all times.
Check the gross weight that is indicated on the package in order to select proper lifting
equipment.
Position and fastening
The pump or pump unit can be transported only horizontally. Make sure that the pump or pump
unit is securely fastened during transportation and cannot roll or fall over.
WARNING:
Do not use eyebolts screwed on the motor for handling the whole electric pump unit.
Do not use the shaft end of the pump or of the motor to handle the pump, the motor or the unit.

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• Eyebolts screwed onto the motor may be exclusively used to handle the individual motor
or, in case of a not balanced distribution of weights, to partially lift the unit vertically starting
from a horizontal displacement.
• Pump unit must always be fixed and transported as shown in Figure 5 page 34, and the pump
without motor must be fixed and transported as shown in Figure 6 page 34, Figure 7 on page
34 and Figure 8 on page 35.
Unit without motor
WARNING:
According to machinery directive 2006/42/EC, a pump and motor that are purchased
seperately and then coupled together result in a new machine. The person making the coupling
is responsible for all safety aspects of the combined unit and for CE-marking.
2.3 Storage Guidelines
Storage location
The product must be stored in a covered and dry location free from heat, dirt, and vibrations.
NOTICE:
Protect the product against humidity, heat sources, and mechanical damage.
NOTICE:
Do not place heavy weights on the packed product.
2.3.1 Long-Term Storage
If the unit is stored for more than 6 months, these requirements apply:
• Store in a covered and dry location.
• Store the unit free from heat, dirt, and vibrations.
• Rotate the shaft by hand several times at least every three months.
Refer to the drive unit and coupling manufacturers for their long-term storage procedures.
For questions about possible long-term storage treatment services, please contact your local
sales and service representative.
Ambient temperature
The product must be stored at an ambient temperature from -5°C to +40°C (23°F to 104°F).
3. PRODUCT DESCRIPTION
3.1 Pump Design
The pump is a horizontal pump with volute casing close coupled to standard electric motors.
The pump can be used for handling:

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• Cold or warm water
• Clean liquids
• Liquids which are not chemically and mechanically aggressive to the pump materials.
The product can be supplied as a pump unit (pump and electric motor) or only as a pump.
NOTICE:
If you have purchased a pump without motor, make sure that the motor is suitable for coupling
to the pump.
Intended use
The pump is suitable for:
• Water supply and water treatment
• Cooling and hot water supply in industries and building services
• Irrigation and sprinkler systems
• Heating systems
Additional uses for optional material:
• District heating
• General industry
Improper use
WARNING:
Improper use of the pump may create dangerous conditions and cause personal injury and
damage to property. An improper use of the product leads to the loss of the warranty.
Examples of improper use:
• Liquids not compatible with the pump construction materials
• Hazardous liquids (such as toxic, explosive, flammable, or corrosive liquids)
• Potable liquids other than water (for example, wine or milk)
Examples of improper installation:
• Hazardous locations (such as explosive, or corrosive atmospheres).
• Location where the air temperature is very high or there is poor ventilation.
• Outdoor installations where there is no protection against rain or freezing temperatures.
DANGER:
Do not use this pump to handle flammable and/or explosive liquids.
NOTICE:
• Do not use this pump to handle liquids containing abrasive, solid, or fibrous substances.
• Do not use the pump for flow rates beyond the specified flow rates on the data plate.
Special applications
Contact the local sales and service representative in the following cases:

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• If the density and/or viscosity value of the pumped liquid exceeds the value of water, such as
water with glycol; as it may require a more powerful motor.
• If the pumped liquid is chemically treated (for example softened, deionized, demineralized etc.).
• Any situation that is different from the ones that is described and relate to the nature of the
liquid.
3.2 Pump Denomination
For an explanation of the denomination code for the pump and one example.
3.3 Nameplate
The nameplate is located on the bearing bracket. The name plate lists key product specifications.
The nameplate lists information regarding the impeller and casing material, the mechanical seal
and their materials. For more information, see Figure 1 on page 30.
IMQ or TUV or IRAM or other marks (for electric pump only)
Unless otherwise specified, for products with a mark of electrical-related safety approval, the
approval refers exclusively to the electrical pump.
3.4 Pump Description
Connection dimensions according EN 733 ( models 32-20/26, 40-20/26, 50-20/26/32, 65-
20/26/32, 80-20/26/32, 100-20/26/32, 125-20/26, 150-20/26)
3.5 Material
The metallic parts of the pump that come in contact with water are made of the following:
3.6 Mechanical Seal
Unbalanced single mechanical seal acc. EN 12756, version K.
3.7 Application Limits
Limits of operation
The operating limits of the pump unit regarding pressure, temperature, performance and speed
are shown in the data sheet.
Material Code Material Casing / Impeller Standard/ Optional
CC Cast iron/Cast iron Standard
CB Cast iron/Bronze Standard
DC Ductile iron / Cast iron Standard
DB Ductile iron /Bronze Standard

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• Do not exceed the output given on the motor name plate.
• Avoid sudden changes in temperature (temperature schoks).
• The pump and motor should run evenly and without vibrations; check at least once a week.
Maximum number of starts per hour
Noise level
For the sound pressure levels of pump equipped with standard supplied motor.
kW 0.25-3.00 4.00-7.50 11-15 18.5-22 30-37 45-75 90-160
Starts per hour 60 30 20 15 12 8 4
EA 32/20 0,75 1450 46 EA 32/20 5,5 2950 62
EA 32/20 1,1 1450 47 EA 32/20 7,5 2950 63
EA 32/20 1,5 1450 48 EA 32/20 11 2950 66
EA 32/26 1,1 1450 47 EA 32/26 7,5 2950 63
EA 32/26 1,5 1450 48 EA 32/26 11 2950 66
EA 32/26 2,2 1450 49 EA 32/26 15 2950 67
EA 32/23 3 1450 50 EA 40/20 7,5 2950 63
EA 40/20 0,75 1450 46 EA 40/20 11 2950 66
EA 40/20 1,1 1450 47 EA 40/20 15 2950 67
EA 40/20 1,5 1450 48 EA 40/26 11 2950 66
EA 40/20 2,2 1450 49 EA 40/26 15 2950 67
EA 40/26 1,5 1450 48 EA 40/26 18,5 2950 68
EA 40/26 2,2 1450 49 EA 40/26 22 2950 71
EA 40/26 3 1450 50 EA 50/20 11 2950 66
EA 40/32 2,2 1450 49 EA 50/20 15 2950 67
EA 40/32 3 1450 50 EA 50/20 18,5 2950 68
EA 40/32 4 1450 51 EA 50/20 22 2950 71
EA 40/32 5,5 1450 52 EA 50/26 22 2950 71
EA 50/20 1,1 1450 47 EA 50/26 30 2950 72
EA 50/20 1,5 1450 48 EA 50/26 37 2950 73
EA 50/20 2,2 1450 49 EA 50/26 45 2950 73
EA 50/26 2,2 1450 49 EA 50/32 37 2950 73
EA 50/26 3 1450 50 EA 50/32 45 2950 73
EA 50/26 4 1450 51 EA 50/32 55 2950 74
EA 50/26 5,5 1450 52 EA 50/32 75 2950 75
EA 50/32 4 1450 51 EA 65/20 18,5 2950 68
EA 50/32 5,5 1450 52 EA 65/20 22 2950 71
EA 50/32 7,5 1450 53 EA 65/20 30 2950 72
EA 50/32 11 1450 54 EA 65/20 37 2950 73
EA 65/20 1,5 1450 48 EA 65/26 30 2950 72
EA 65/20 2,2 1450 49 EA 65/26 37 2950 73
EA 65/20 3 1450 50 EA 65/26 45 2950 73
EA 65/20 4 1450 51 EA 65/26 55 2950 74
EA 65/26 4 1450 51 EA 65/32 55 2950 74
EA 65/26 5,5 1450 52 EA 65/32 75 2950 75
EA 65/26 7,5 1450 53 EA 65/32 90 2950 76
EA 65/32 4 1450 51 EA 80/20 18,5 2950 68
EA 65/32 5,5 1450 52 EA 80/20 22 2950 71
EA 65/32 7,5 1450 53 EA 80/20 30 2950 72
EA 80/20 3 1450 50 EA 80/20 37 2950 73
EA 80/20 4 1450 51 EA 80/20 45 2950 73
EA 80/20 5,5 1450 52 EA 80/26 37 2950 73
EA 80-26 4 1450 51 EA 80-26 45 2950 73
EA 80-26 5,5 1450 52 EA 80-26 55 2950 74
EA 80-26 7,5 1450 53 EA 80-26 75 2950 75
EA 80-26 11 1450 54 EA 80-32 90 2950 76
EA 80-32 11 1450 54 EA 80-32 110 2950 77
EA 80-32 15 1450 55 EA 80-32 132 2950 78
EA 80-32 11 1450 54 EA 80-32 160 2950 78
EA 100-20 3 1450 50 EA 100-20 30 2950 72
EA 100-20 4 1450 51 EA 100-20 37 2950 73
EA 100-20 5,5 1450 52 EA 100-20 45 2950 73
EA 100-20 7,5 1450 53 EA 100-20 55 2950 74
EA 100-26 5,5 1450 52 EA 100-26 45 2950 73
EA 100-26 7,5 1450 53 EA 100-26 55 2950 74
EA 100-26 11 1450 54 EA 100-26 75 2950 75
EA 100-32 11 1450 54 EA 100-26 90 2950 76
EA 100-32 15 1450 55 EA 100-32 110 2950 77
EA 100-32 18,5 1450 63 EA 100-32 132 2950 78
EA 100-32 160 2950 78
PUMP TYPE POWER
[kW] SPEED [rpm] SOUND P. LEVEL
[dB(A)]
PUMP TYPE POWER
[kW] SPEED [rpm] SOUND P. LEVEL
[dB(A)]
EA PUMP SOUND PRESSURE LEVEL [dB(A)]
Sound pressure level measurements were made with 50 Hz electric motors with noiseless environment.

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4.INSTALLATION
Precautions
WARNING:
• Observe accident prevention regulations in force.
• Use suitable equipment and protection.
• Always refer to the local and/or national regulations, legislation, and codes in force regarding
the selection of the installation site, plumbing, and power connections.
Electrical Hazard:
• Make sure that all connections are performed by qualified installation the regulations in force.
• Before starting work on the unit, make sure that the unit and the control panel are isolated from
the power supply and cannot be energized. This applies to the control circuit as well.
Grounding (earthing)
Electrical Hazard:
• Always connect the external protection conductor to ground (earth) terminal before making
other electrical connections.
• You must ground (earth) all electrical equipment. This applies to the pump equipment, the
driver, and any monitoring equipment. Test the ground (earth) lead to verify that it is connected
correctly.
• If the motor cable is jerked loose by mistake, the ground (earth) conductor should be the last
conductor to come loose from its terminal. Make sure that the ground (earth) conductor is
longer than the phase conductors. This applies to both ends of the motor cable.
• Add additional protection against lethal shock. Install a high-sensitivity differential switch (30
mA) [residual current device RCD].
4.1 Facility Requirements
4.1.1 Pump location
DANGER:
Do not use this unit in environments that may contain flammable/explosive or chemically
aggressive gases or powders.
Guidelines
Observe the following guidelines regarding the location of the product:
• Make sure that no obstructions hinder the normal flow of the cooling air that is delivered by the
motor fan.
• Make sure that the installation area is protected from any fluid leaks, or flooding.
• If possible, place the pump slightly higher than the floor level.
• The ambient temperature must be between 0°C (+32°F) and +40°C (+104°F).
• The relative humidity of the ambient air must be less than 50% at +40°C (+104°F).
• Contact the Sales and Service Department if:

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– The relative air humidity conditions exceed the guidelines.
– The room temperature exceeds +40°C (+104°F).
– The unit is located more than 1000 m (3000 ft) above the sea level. The motor performance
may need to be de-rated or replaced with a more powerful motor
Pump positions and clearance
Provide adequate light and clearance around the pump. Make sure that it is easily accessible for
installation and maintenance operations.
Installation above liquid source (suction lift)
The theoretical maximum suction height of any pump is 10.33m. In practice, the following affect
the suction capacity of the pump:
• Temperature of the liquid
• Elevation above the sea level (in an open system)
• System pressure (in a closed system)
• Resistance of the pipes
• Own intrinsic flow resistance of the pump
• Height differences
The following equation is used to calculate the maximum height above the liquid level which the
pump can be installed:
(pb*10.2 - Z) ≥ NPSH + Hf + Hv + 0.5
Pb: Barometric pressure in bar (in closed system is system pressure)
NPSH: Value in meter of the pump intrinsic flow resistance
Hf: Total losses in meters caused by passage of liquid in the suction pipe of the pump
Hv: Steam pressure in meters that correspond to the temperature of the liquid T °C
0.5: Recommended safety margin (m)
Z: Maximum height at which the pump can be installed (m)
(pb*10.2 - Z) must always be a positive number. For more information Fig. 6 page 34.
NOTICE:
Do not exceed the pumps suction capacity as this could cause cavitation and damage the pump.
4.1.2 Piping Requirements
Precautions
WARNING:
• Use pipes suited to the maximum working pressure of the pump. Failure to do so can cause
the system to rupture, with the risk of injury.
• Make sure that all connections are performed by qualified installation technicians and in
compliance with the regulations in force.
NOTICE:
Observe all regulations issued by authorities having jurisdiction and by companies managing
the public water supplies if the pump is connected to a public water system. If required, install
appropriate backflow- prevention device on the suction side.

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Piping Requirements Checklist
Check that the following requirements are met:
• All piping is independently supported, piping must not place a burden on the unit.
• Flexible pipes or unions are used, in order to avoid transmission of pump vibrations to the
pipes and vice versa.
• Use wide bends, avoid using elbows which cause excessive flow resistance.
• The suction piping is perfectly sealed and airtight.
• If the pump is used in an open circuit, then the diameter of the suction pipe is suited to the
installation conditions. The suction pipe must not be smaller than the diameter of the suction
port.
• If the suction piping must be larger than the suction side of the pump, then an eccentric pipe
reducer is installed.
• If the pump is placed above liquid level, a foot valve is installed at the end of the suction piping.
• The foot valve is fully immersed into the liquid so that air cannot enter through the suction
vortex, when the liquid is at the minimum level and the pump is installed above the liquid
source.
• Appropriately sized on-off valves are installed on the suction piping and on the delivery piping
(downstream to the check valve) for regulation of the pump capacity, for pump inspection, and
for maintenance.
• Appropriately sized on-off valve is installed on the delivery piping (downstream to the check
valve) for regulation of the pump capacity, for pump inspection, and for maintenance.
• In order to prevent back flow into the pump when pump is turned off a check valve is installed
on the delivery piping.
WARNING:
Do not use the on-off valve on the discharge side in the closed position in order to throttle the
pump for more than a few seconds. If the pump must operate with the discharge side closed for
more than a few seconds, a bypass circuit must be installed to prevent overheating of the liquid
inside the pump.
For illustrations that show the piping requirements, see Figure 12 – 13 page 36.
4.2 Electrical Requirements
• The local regulations in force overrule these specified requirements.
• In the case of fire fighting systems (hydrants and/or sprinklers), check the local regulations in
force.
Electrical connection checklist
Check that the following requirements are met:
• The electrical leads are protected from high temperature, vibrations, and collisions.
• The power supply line is provided with:
– A short-circuit protection device
– A mains isolator switch with a contact gap of at least 3 mm

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The electrical control panel checklist
NOTICE:
The control panel must match the ratings of the electric pump. Improper combinations could
fail to guarantee the protection of the motor.
Check that the following requirements are met:
• The control panel must protect the motor against overload and short-circuit.
• Install the correct overload protection (thermal relay or motor protector).
The control panel must be equipped with a dry running protection system to which a pressure
switch, float switch, probes, or other suitable device is connected.
• The following devices are recommended for use on the suction side of the pump:
When the liquid is pumped from a water system, use a pressure switch.
When the liquid is pumped from a storage tank or reservoir, use a float switch or probes.
• When thermal relays are used, relays that are sensitive to phase failure are recommended.
The motor checklist
WARNING:
• Read the operating instructions in order to ensure whether a protection device is provided if
another motor other than the standard is used.
• If the motor is equipped with automatic thermal protectors, be aware of the risk of
unexpected starts in Connection to overload. Do not use such motors for fire-fighting
applications.
NOTICE:
• Only use dynamically balanced motors with a half-sized key in the shaft extension (IEC
60034-14) and with normal vibration rate (N).
• The mains voltage and frequency must agree with the specifications on the data plate.
In general, motors can operate under the following mains voltage tolerances:
Use cable according to rules with 3 leads (2+earth/ ground) for single phase versions and with 4
leads (3+earth/ground) for three phase version.
Pump Type Protection
Single phase standard
electric pump ≤ 2,2 kW
– Built-in automatic reset thermal amperometric
protection (motor protector)
– Short circuit protection (must be supplied by the installer)3
Three phase electric pump4– Thermal protection (must be supplied by the installer)
– Short circuit protection (must be supplied by the installer)
Frequency Hz Phase ~ UN [V] ± %
50
1 220 – 240 ± 6
3230/400 ± 10
400/690 ± 10
60 1 220 – 230 ± 6
3220/380 ± 5
380/660 ± 10

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4.3 Install the Pump
4.3.1 Mechanical Installation
Check the following before installation:
• Use a concrete of compressive strength class C12/15 which meets the requirements of
exposure class XC1 to EN 206-1.
• The mounting surface must have set and must be completely horizontal and even.
• Observe the weights indicated.
Install the pump set
For examples of horizontal installations, see Figure 8 page 35. Check that the foundation
has been prepared in accordance with the dimensions given in the outline drawing/general
arrangement drawing.
1. Position the pump set on the foundation and level it with the help of a spirit level that is
placed on the discharge port. The permissible deviation is 0.2 mm/m.
2. Remove the plugs covering the ports.
3. Align the pump and piping flanges on both sides of the pump. Check the alignment of the
bolts.
4. Fasten the piping with bolts to the pump. Do not force the piping into place.
5. Use shims for height compensation, if necessary. Always fit shims, if any, immediately to the
left and right of the foundation bolts between the baseplate/foundation. For a bolt-to-bolt
distance (L)>800 mm, fit extra shims halfway between the bolt holes.
6. Make sure that all shims lie perfectly flush.
7. Insert the foundation bolts into the holes provided.
8. Use concrete to set the foundation bolts into the foundation.
9. Wait until the concrete has set firmly, and then level the baseplate.
10. Tighten the foundation bolts evenly and firmly.
Note:
• For baseplates, it is recommended to grout the baseplate with low-shrinkage concrete.
• If the transmission of vibration-damping supports between the pump and the foundation.
Mount the pump to a base frame
Be sure to check that the following are adhered to:
• Solid base frame which does not twist or vibrate during operation (resonance)
• Mounting surfaces of the pump feet and the motor on the base frame must be flat(machining
is recommended)
• Safe fastening of pump and motor must be guaranteed.
• Adequate space between pump or motor shaft must be left depending on the used
coupling.
• Between pump and base frame must be an adequate shimming, so that in case
of replacement the same height between bottom and centerline can be adjusted
(recommended vertical adjustment 47-6 mm)

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4.3.2 Piping Checklist
Check that the following are adhered to:
• The suction lift line has been laid with a rising slope, at positive suction head line with a
downward slope towards the pump Fig. 6 page 34.
• The nominal diameters of the pipelines are at least equal to the nominal diameters of the pump ports.
• The pipelines have been anchored in close proximity to the pump and connected without
transmitting any stresses or strains Fig. 7 page 34
CAUTION:
Welding beads, scale and other impurities in the piping damage the pump.
• Free the piping from any impurities.
• If necessary, install a filter.
4.3.3 Coupling Alignment
After mounting to the foundation and the Connection of the piping, the coupling must be
adjusted again, even if the unit was delivered completely mounted on the frame.
Remove the coupling guard
‘Wire mesh’ type and/or sheet typ
For information see Fig. 9 on page 35.
1. Unscrew the fixing devices (2).
2. Open the lift guard (1).
– Do not loosen screws, washers and nuts.
‘Shell’ type
1. Unscrew the fixing devices — side (2).
2. Unscrew the fixing devices — up (2).
3. Remove the coupling guard — upper half (1).
4. Unscrew the fixing devices — low (2).
5. Remove the coupling guard.
Alignment
For information see Figure 10 on page 35
1. Loosen screws of the support and pump foot.
2. Place the ruler (1) axially on both coupling halves.
3. Leave the ruler (1) in this position and turn the coupling by hand.
– The coupling is aligned correctly if the distances ‘a’ and ‘b’ to the respective shafts are the same
at all points around the circumference.
– The radial and axial deviation between the two coupling halves must not exceed the values
set by the manufacturer, during standstill as well as at operating temperature and under inlet
pressure.

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4. Check the distance between the two coupling halves around the circumference with a gauge (2).
– The coupling is aligned correctly if the distance between the two coupling halves is the same at
all points around the circumference.
– The radial and axial deviation between the two coupling halves must not exceed the values set by
the manufacturer, during stand still as well as at operating temperature and under inlet pressure.
5. Re-tighten screws of the support and pump foot without transmitting any stresses and strains.
Dial gauges can be used in the place of ruler and thickness gauge.
Contact the local sales and service representative for any requests or information.
NOTE: Check alignment of coupling again in operation warm condition and on system pressure if
available and correct, if necessary. Be sure that the unit can be easily turned by hand.
NOTICE: Improper alignment of the unit can lead to damages at coupling and unit.
Install the coupling guard
CAUTION: Never operate the pump without the coupling guard correctly installed.
‘Wire mesh’ type
For information see Figure 9 on page 35.
1. Open and place the guard (1) in a way that it envelops the bearing cover and the supporting/
adjusting ring (3).
2. Press the supporting/adjusting ring (3) axially to the motor.
3. Screw the fixing devices (2).
‘Shell’ type
For information see Figure 9 on page 36
1. Place the coupling guard — lower half (2) using the fixing devices — low (4).
2. Open and insert the supporting/adjusting ring (3) with slot downward and press it axially to the
motor.
3. Place the coupling guard — upper half (1) using the fixing devices — up (2).
4. Screw the fixing devices — side (2).
4.3.4 Electrical Installation
1. Remove the screws of the terminal box cover.
2. Connect and fasten the power cables according to the applicable wiring diagram.
For wiring diagrams, see Figure 11 on page 36. The diagrams are also available on the back of the
terminal box cover.
a) Connect the ground (earth) lead.
Make sure that the ground (earth) lead is longer than the phase leads.
b) Connect the phase leads.
3. Mount the terminal box cover.

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NOTICE: Tighten the cable glands carefully to ensure protection against cable slipping and
humidity entering the terminal box.
4. If the motor is not equipped with automatic reset thermal protection, then adjust the overload
protection according to the list below.
– If the motor is used with full load, then set the value to the nominal current value of electric
pump (data plate)
– If the motor is used with partial load, then set the value to the operating current (for example
measured with a current pincer).
– If the pump has a star-delta starting system, then adjust the thermal relay to 58% of the
nominal current or operating current (only for three-phase motors).
5. COMMISSIONING, STARTUP, OPERATION, AND SHUTDOWN
Precautions
WARNING:
• Make sure that the drained liquid does not cause damage or injuries.
• The motor protectors can cause the motor to restart unexpectedly. This could result in serious
injury.
• Never operate the pump without the coupling guard correctly installed.
CAUTION:
• The outer surfaces of the pump and motor can exceed 40ºC (104ºF) during operation. Do not
touch with any part of the body without protective gear.
• Do not put any combustible material near the pump.
NOTICE:
• Never operate the pump below the minimum rated flow, when dry, or without prime.
• Never operate the pump with the delivery ON/OFF valve closed for longer than a few seconds.
• Never operate the pump with the suction ON/OFF valve closed.
• Do not expose an idle pump to freezing conditions. Drain all liquid that is inside the pump.
Failure to do so can cause liquid to freeze and damage the pump.
• The sum of the pressure on the suction side (mains, gravity tank) and the maximum pressure
that is delivered by the pump must not exceed the maximum working pressure that is allowed
(nominal pressure PN) for the pump.
• Do not use the pump if cavitation occurs. Cavitation can damage the internal components.
5.1 Fill the Pump
For information about additional pump connections, see Figure 12 on page 36.
Installations with liquid level above the pump (suction head)
For an illustration that shows where pump plugs are, see Figure 13 on page 36.
1. Close the on-off valve located downstream from the pump.
2. Remove the fill (3) or gauge plug (1) and open the on/off valve upstream until the water flows
out of the hole. a) Close the fill (3) or gauge plug (1).

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Installations with liquid level below the pump (suction lift)
For an illustration that shows where pump plugs are, see Figure 12 on page 36.
1. All pipe system empty:
a) Open the on-off valve located upstream from the pump.
b) Remove the fill plug (3) and the gauge plug (1). Use a funnel to fill the pump through the
fill hole until the water flows out of this hole.
c) Tighten the fill plug (3) and the gauge plug (1).
2. Filled discharge pipe system:
a) Open the on-off valve located upstream from the pump and open the on-off valve
downstream.
b) Remove the gauge plug (1) until water flows out of this hole.
c) Tighten the gauge plug (1).
5.2 Check the Rotation Direction (Three-phase Motors)
Follow this procedure before start-up.
1. Locate the arrows on the adaptor or the motor fan cover to determine the correct rotation direction.
2. Start the motor.
3. Quickly check the direction of rotation through the coupling guard or through the motor fan cover.
4. Stop the motor.
5. If the rotation direction is incorrect, then do as follows:
a) Disconnect the power supply.
b) In the terminal board of the motor or in the electric control panel, exchange the position of
two of the three wires of the supply cable. For the wiring diagrams, see Figure 11 on page 36.
c) Check the direction of rotation again.
5.3 Start the Pump
The responsibility for checking the correct flow and the temperature of the pumped liquid rests
with the installer or owner.
Before starting the pump, make sure that:
• The pump is correctly connected to the power supply.
• The pump is correctly filled according to instructions in Fill the pump (chapter 5).
• The on-off valve located downstream from the pump is closed.
1. Start the motor.
2. Gradually open the on-off valve on the discharge side of the pump.
At the expected operating conditions, the pump must run smoothly and quietly. If not, refer to
Troubleshooting on page 27-30.
6.MAINTENANCE
Precautions
Electrical Hazard: Disconnect and lock out electrical power before installing or servicing the unit.

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WARNING:
• Maintenance and service must be performed by skilled and qualified personnel only.
• Observe accident prevention regulations in force.
• Use suitable equipment and protection.
• Make sure that the drained liquid does not cause damage or injuries.
6.1 Service
If the user wishes to schedule regular maintenance deadlines, they are dependent on the type of
pumped liquid and on the operating conditions of the pump.
Contact the local sales and service representative for any requests or information regarding
routine maintenance or service.
Extraordinary maintenance may be necessary to clean the liquid end and/or replace worn parts.
Pumps with greased for life bearings
Pumps with greased for life bearings do not require any scheduled routine maintenance.
Pumps with re-greaseable bearings
• Regrease at 4000 operating hours, but at least once per year. Clean lubrication nipples (SN) first.
• Use NLGI Grade 2 grease or equivalent.
Contact the local sales and service representative for any requests or information.
Motor bearings
After approximately five years, the grease in the motor bearings is so aged that a replacement of
the bearings is recommended. The bearings must be replaced after 25000 operating hours or
according to the motor supplier maintenance instructions, whichever is shorter.
Motor with regreasable bearings
Follow motor supplier maintenance instructions.
Coupling
Check the clearance in the coupling elements regularly, at least once a year. We recommend
checking every 1000 operating hours or every three months, whichever comes first.
6.2. Inspection Checklist
Check the coupling Check the flexible elements of the coupling. Replace the relevant
parts if there is any sign of wear and check the alignment.
Check the mechanical seal Check for leakage of the mechanical seal. Re- place the
mechanical seal if leakage is found.
Checking the bearing seals Check correct seating of axial seal rings mounted on the shaft.
Only gentle contact of the sealing lip shall be established.
Check for quiet running Check frequently for quiet running of the pump with vibration
measurement tools.

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7. DISMANTLING AND REPAIR OF PUMP
7.1 General Remarks
Repair to the pump or pump system may only be carried out by authorised skilled
personnel or by the manufacturer´s specialist staff.
When disassembling the pump pay attention to chapter 1 and chapter 2.
If dangerous liquids are pumped the appropriate disposal of the handled liquid is
necessary before the disassembly of the pump. Pay attention to the fact, that even in
drained pumps there are remainders of the handled liquid. If necessary the pump must be
flushed or decontaminated. Laws must be observed, otherwise danger to health is existing!
• Before the disassembly the pump has to be secured in such a way, that it can´t be started.
• The pump casing must be drained and without pressure.
• All locking devices in the suction- and discharge-pipe must be closed.
• All parts must have taken on the temperature of the environment.
Secure disassembled pumps, units or single parts against tipping over or rolling off.
While disassembling the pump use of an open flame (blowlamp, etc.) only, when there is no
danger of setting fire, cause an explosion or cause injurious vapours. Never apply heat to
remove the impeller nut. Use of heat may result in severe physical injury and property damage.
Use original spare parts only. Pay attention to the right materials and the matching design.
7.2 General
Works, which require shocks (hammer), must only be performed outside the explosive
atmosphere or only non-sparking tools must be used.
Carry out disassembly and mounting according to the appropriate sectional drawing (Technical
Appendix page 43-44). You will only need common tools. Before disassembly check if required parts
are ready. Disassemble the pump only so far, as required for the replacement of the repair part.
7.3 Disassembly of Back Pull Out Assembly
The Back Pull Out Assembly includes all parts of the pump except the volute casing . As the pumps
are constructed for process design the volute casing can stay on the base frame and in the pipes,
unless the volute casing itself must be repaired.
• Drain volute casing through the drain plug.
• Remove coupling guard.
• Remove spacer of the spacer type coupling.
• Loosen screws for support foot from the base frame.
• Hang the Back Pull Out Assembly onto a lifting device, so that it won´t sink down or press into
the volute casing during the dismounting. Example see picture 1 for lifting recommendations.

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• Loosen hexagon head bolt from the
casing.
• Using the jack belts provided,
separate the Back Pull Out Assembly
from the casing.
7.4. Removal of the Mech. Seal
Use the sectional drawing and data
sheet of the mech. seal for this purpose.
• Remove and disassemble the
pump according to the Installation,
Operation and Maintenance
Instructions including chapter 7.
• Remove the rotating part of the mech.
seal from shaft.
Remove the stationary part of the mech. seal out of the seal chamber cover.
Clean mounting holes (Ød7) in the seal chambers cover and surface of shaft.
The reuse of mech. seals that have already been used for a longer time can lead
to leaking at the seal faces after reinstallation. Therefore the replacement of the
mech. seal with a new one is recommended. The removed mechanical seal can be
reconditioned by the manufacturer and serve as a replacement mech. seal.
7.5 Installation of the Mech. Seal
Use the sectional drawing and data sheet of the mech. seal for this purpose.
Only mech. seals that have a certificate of Conformity according to the Directive 94/9/
EC may be installed. On changing the mech. seal type or the mech. seal manufacturer,
the data regarding max. operating temperature of the pumped medium and
temperature class must be checked again.
Pay attention to the utmost cleanness! Especially the seal faces must be clean, dry and
undamaged. Don't apply lubrication on the seal faces of the mech. seal.
• If a lubricant is provided with the replacement mech. seal, you should use this.
Use mineral grease or oil only if you are completely sure that the elastomers of the
mech. seal are oil resistant. Use no silicone.
Use only lubricants with which you are certain that no dangerous reaction can occur
between the lubricant and the pumped medium.
Have all required parts prepared so that assembly can be completed quickly. The
lubricants are only effective for a short time. After that, the axial mobility and thus the
automatic adjustment of the elastomers is lost.
Never push elastomers over sharp edges. If necessary, use mounting devices.
Picture 1