ITT ICB Manual

Goulds Pumps
Artikel Nr. 771076102 Rev. 02 01/2010
en
Goulds-Volute Casing Pumps
Model: ICB
Installation, Operation and Maintenance Instruction
Translation of the Original Operation Manual
en
Keep for further use !
Pay attention to this operating instruction before the delivery, installation, start-up a.s.o.!
© ITT Austria GmbH

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 1 Revision 02
Article No 771076102 Issue 01/2010
TABLE of CONTENTS
Pump Name Plate ..................................................... 2
ATEX-Label (only for pumps in compliance with
EC directive 94/9/EG)................................................ 2
1. General................................................................... 3
1.1 Guarantee ......................................................... 3
2. Safety Regulations ............................................... 3
2.1 Marking of References in the Operating
Instructions.............................................................. 3
2.2 Dangers of non-observance of the Safety
Instructions.............................................................. 4
2.3 Safety Instructions for the Operator / Worker ... 4
2.4 Safety Instructions for Maintenance, Inspections
and Mounting Work ................................................. 4
2.5 Unauthorized Alteration and Spare Parts
Production ............................................................... 4
2.6 Undue Operation............................................... 4
2.7 Explosion Protection.......................................... 4
2.8 Use acc. to Regulations .................................... 6
3. Description ............................................................ 6
3.1 Design ............................................................... 6
3.1.1 Design Coding System................................... 6
3.2 Shaft Sealing ..................................................... 7
3.3 Bearing .............................................................. 7
3.4 Approximate Value for Sound Pressure Level .. 7
3.5 Permitted Nozzle Loads and Torques at the
Pump Nozzles ... ..................................................... 7
3.6 Permitted pressures and temperatures............. 8
3.7 Condensate ....................................................... 9
4. Transport, Handling, Storage .............................. 9
4.1 Transport, Handling........................................... 9
4.2 Storage / Conservation...................................... 9
5. Mounting / Installation ......................................... 9
5.1 Mounting of Pump / Unit.................................... 9
5.2 Connection of Pipings to the Pump................. 10
5.3 Drive................................................................ 10
5.4 Electric Connection ......................................... 10
5.5 Final Control .................................................... 11
6. Start-up, Operation, Shut down ........................ 11
6.1 Initial start-up................................................... 11
6.2 Switch on drive................................................ 11
6.3 Restarting ........................................................11
6.4 Limits of Operation ..........................................11
6.5 Lubrication .......................................................12
6.6 Monitoring ........................................................12
6.7 Shutting down ..................................................12
6.8 Storage / longer periods of non-operation .......12
7. Servicing, Maintenance ......................................13
7.1 General remarks..............................................13
7.2 Mechanical seals .............................................13
7.3 Motor bearings.................................................13
7.4 Cleaning of pump ............................................13
8. Dismantling and repair of pump ........................13
8.1 General remarks..............................................13
8.2 General............................................................13
8.3 Removal and Installation of screen in the motor
lantern....................................................................13
8.4 Removal of the Back Pull Out Assembly .........14
8.5 Removal of Impeller.........................................14
8.6 Removal of Shaft Sealing ................................14
8.7 Removal of Stub Shaft.....................................14
8.8 Reconditioning .................................................15
8.9 Mounting ..........................................................15
9. Spare parts, Spare pumps..................................16
9.1 Spare parts ......................................................16
9.2 Stand-by pumps...............................................16
10. Faults - Causes and Solutions.........................17
11. Motor Operating Instructions ..........................18
Installation Manual - Single mech. seal without shaft
sleeve (Design code S1..2) .......................................20
Installation Manual - Single mech. seal with quench
without shaft sleeve (Design code S4..2) ………...... 22
Sectional drawing pump unit (Design code S1..2),
Impeller with back vanes.......................................... 25
Sectional drawing pump unit (Design code S1..2),
Impeller with balancing holes ................................... 26
Sectional drawing pump unit (Design code S4..2),
Impeller with back vanes.......................................... 27
Sectional drawing pump unit (Design code S4..2),
Impeller with balancing holes ................................... 28
Connections ............................................................. 29
Dimensional drawing................................................ 30

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 2 Revision 02
Article No 771076102 Issue 01/2010
Pump Name Plate
Type *) Type of pump
S/N *) Serial number
Year Year of construction
Q Rated capacity at the operating point
P Rated power at the operating point
H Head (Energy head) at the operating point
n Speed
p
all w C
Max. permitted casing-operation-pressure
(=highest discharge pressure at the rated
operating temperature to which the pump
casing can be used).
t
max op
Maximum permitted operating temperature of
pumped liquid
Item NoCustomer related order number
Imp∅Outer diameter of the impeller
*) All details of design and materials are defined with
this information. They must be stated on all inquiries to
the manufacturer resp. orders of spare.
ATEX-Label (only for pumps in compliance with EC directive 94/9/EG)
CE Marking of compliance with the EC directive
94/9/EG
Ex specific marking for explosion protection
II Symbol for the appliance group
2G Symbol for the category (2), explosive
atmosphere due to gases, vapors or mist (G)
c Symbol for used ignition protection
(constructual safety "c")
T1-T. Symbol for classification of the theoretically
available range of the temperature classes -
data for temperature class refer to chapter
2.7.5; Data for maximum permitted
temperature of pumped liquid refer to pump
name plate, data sheet and / or order
confirmation.
The conformity with the EC directive 94/9/EG
"Appliances and Protection Systems for designated
use in areas endangered to explosion" is declared by
the issue of the EC-Declaration of Conformity and the
attachment of the ATEX-label at the pump (adapter).
The ATEX-label is attached additionally to the pump
name plate.

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 3 Revision 02
Article No 771076102 Issue 01/2010
1. General
This product corresponds with the requirements of the
Machine directive 2006/42/EG.
The staff employed on installation, operation,
inspection and maintenance must be able to
prove that they know about the relevant
accident preven
tion regulations and that they
are suitably qualified for this work. If the staff
does not have the relevant knowledge, they
should be provided with suitable instruction.
The operation safety of the delivered pump resp. unit
(= pump with motor) can only be guaranteed on
designated use according to the attached data sheet
and / or order confirmation resp. chapter 6 "Start-up,
Operation, Shut down".
The operator is responsible for following the
instructions and complying with the safety
requirements given in these Operating Instructions.
Smooth operation of the pump or pump unit can only
be achieved if installation and maintenance are carried
out carefully in accordance with the rules generally
applied in the field of engineering and electrical
engineering.
If not all the information can be found in these
Operating Instructions, please contact us.
The manufacturer takes no responsibility for the pump
or pump unit if the Operating Instructions are not
followed.
These Operating Instructions should be kept in a safe
place for future use.
If this pump or pump unit is handed on to any third
party, it is essential that these Operating Instructions
and the operating conditions and working limits given
in the Confirmation of Order are also passed on in full.
These Operating Instructions do not take into account
all design details and variants nor all the possible
chance occurrences and events which might happen
during installation, operation and maintenance.
We retain all copyright in these Operating Instructions;
they are intended only for personal use by the owner
of the pump or the pump unit. The Operating
Instructions contain technical instructions and
drawings which may not, as a whole or in part, be
reproduced, distributed or used in any unauthorised
way for competitive purposes or passed on to others.
1.1 Guarantee
The guarantee is given in accordance with our
Conditions of Delivery and / or the confirmation of
order.
Repair work during the guarantee period may only be
carried out by us, or subject to our written approval.
Otherwise the guarantee ceases to apply.
Longer-term guarantees basically only cover correct
handling and use of the specified material. The
guarantee shall not cover natural wear and tear and all
parts subject to wear, such as impellers, shaft
sealings, shafts, shaft sleeves, bearings, wear rings
etc. or damage caused by transport or improper
handling.
In order for the guarantee to apply, it is essential that
the pump or pump unit is used in accordance with the
operating conditions given on the name plate,
confirmation of order and in the data sheet. This
applies particularly for the endurance of the materials
and smooth running of the pump and shaft sealing.
If one or more aspects of the actual operating
conditions are different, we should be asked to
confirm in writing that the pump is suitable.
2. Safety Regulations
These Operating Instructions contain important
instructions which must be followed when the pump is
assembled and commissioned and during operating
and maintenance. For this reason, these Operating
Instructions must be read by the skilled staff
responsible and / or by the operator of the plant before
it is installed and commissioned, and they must be left
permanently available at the place where the pump or
pump unit is in use.
These Operating Instructions do not refer to the
General Regulations on Accident Prevention or
local safety and / or operating regulations. The
operator is responsible for complying with these
(if necessary by calling in additional installation
staff).
Equally, instructions and safety devices regarding
handling and disposal of the pumped media and/or
auxilliary media for flushing, lubrication a.s.o.,
especially if they are explosive, toxical, hot a.s.o., are
not part of this operating instruction.
For the competent and prescribed handling only the
operator is responsible.
2.1 Marking of References in the
Operating Instructions
The safety regulations contained in these Operating
Instructions are specially marked with safety signs
acc. to nach DIN 4844:
Safety reference!
Non-
observance can impair the pump and its
function.
EC-Ex Marking
Products intended for use in explosive
atmospheres must be marked.
General Symbol for Danger!
Persons can be endangered.
Warning of electric voltage!

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 4 Revision 02
Article No 771076102 Issue 01/2010
Safety instructions attached directly to the pump resp.
unit must be followed under any circumstances.
Further they must be kept in good readable condition.
In the same way, as these Operating Instructions
of the pump, all possibly attached Operating
Instructions of accessories (e.g. motor) must be
noticed and kept available.
2.2 Dangers of non-observance of the
Safety Instructions
Non-observance of the Safety Instructions can
lead to loss of any claim for damages.
Further, non-observance can lead to following risks:
Failure of important functions of the machine or
facility.
Failure of electronic appliances and measuring
instruments by magnetic fields.
Endangering of persons and their personal
property by magnetic fields.
Endangering of persons by electric, mechanic and
chemical influences.
Endangering of environment through leakage of
dangerous substances.
On application of the unit in areas endangered
to explosion special attention must be paid to
sections marked with Ex.
2.3 Safety Instructions for the Operator /
Worker
Depending on the operating conditions, wear and
tear, corrosion or age will limit the working life of
the pump/pump unit, and its specified
characteristics. The operator must ensure that
regular inspection and maintenance are carried
out so that all parts are replaced in good time,
which would otherwise endanger the safe
operation of the system. If abnormal operation or
any damage are observed, the pump must cease
operation immediately.
If the breakdown or failure of any system or unit
could lead to people being hurt or property being
damaged, such system or unit must be provided
with alarm devices and/or spare modules, and
they should be tested regularly to ensure that they
function properly.
If there is any risk of injury from hot or cold
machine parts, these parts must be protected
against contact by the user, or suitable warning
signs must be affixed.
Contact protection on moving parts (e.g. coupling
guards) must not be removed from systems that
are in operation.
If the sound level of a pump or pump unit is above
85 dB(A) an ear protection has to be used when
staying near the pump for some time.
If dangerous media (e.g. explosive, toxic, hot) leak
out (e.g. from shaft seals), these must be directed
away so that there is no danger to people or the
environment. The provisions of the law must be
observed.
Measures should be taken to exclude any danger
from electricity (e.g. by complying with the local
regulations on electrical equipment). If work is
carried out on live electrical components, they
should be unplugged from the mains or the main
switch turned off and fuse unscrewed. A motor
protection switch is to be provided.
2.4 Safety Instructions for Maintenance,
Inspections and Mounting Work
The operator is responsible that any maintenance,
inspections and mounting work is made by
authorized competent personnel, which must be
informed by having read the Operating
Instructions.
Basically, all work on the pump or pump unit
should only be carried out when the pump is
stationary and not under pressure. All parts must
be allowed to return to ambient temperature.
Make sure that no-one can start the motor during
such work. It is essential that the procedure for
stopping the system described in the Operating
Instructions is observed. Pumps or pump systems
that carry media that are dangerous to health must
be decontaminated before being taken apart.
Safety Data Sheets for the various liquids handled.
Immediately after finishing work, all safety and
protective devices must be replaced or restarted.
2.5 Unauthorized Alteration and Spare
Parts Production
Alteration or changes of the machine are permitted
after agreement with the manufacturer.
Original spare parts and accessory authorized by the
manufacturer are serving the safety.
The use of other parts can lead to loss of liability for
therefrom resulting consequences.
2.6 Undue Operation
The operating safety of the delivered machine can
only be guaranteed by designated use acc. to the
following chapters of the Operating Instructions.
The limits stated in the data sheet and / or order
confirmation must not be exceeded under any
circumstances.
2.7 Explosion Protection
On application of units in areas endangered to
explosion measures and references in the chapters
2.7.1 to 2.7.6 must be observed, so that explosion
protection is guaranteed.
2.7.1 Filling of unit
During operation of the pump the system of the
suction and pressure pipe and the pump itself
must permanently be filled with the pumped
liquid.
Thus, no explosive atmosphere can develop
and the danger of dry-run is avoided.

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 5 Revision 02
Article No 771076102 Issue 01/2010
If the operator can´t guarantee that, according
monitoring measures must be provided.
Equally all seal casings, auxiliary systems of the
shaft sealing, as well as heating and cooling
systems must be filled carefully.
2.7.2 Marking
The marking of the pump refers to the pump
itself. For the motor resp. further addi
tions a
separate Declaration of Conformity, as well as a
corresponding marking must be available.
Example of of marking at pump:
CE Ex II 2 G c T1-T.
The marking shows the theoretically applicable range
of temperature classes. The different temperatures,
permitted acc. to pump design, result as shown in
chapter 2.7.5. The same is valid for the drive.
For a whole unit (pump, motor) with different
temperature classes the lowest is valid.
2.7.3 Rotation Control
If danger of explosion is also existing during
installation, the rotation control must not be
carried out by short start-
up of the empty pump,
to avoid undue temperature increase in case of
contact of rotating and stationary parts.
2.7.4 Operation of pump
The pump must only be started up with fully opened
suction side and slightly opened pressure side valve.
The start-up against closed non-return valve, however,
is possible. Immediately after the start-up the
discharge side valve must be adjusted to the operating
point.
Refer to chapter 6.2, as well.
Operation with closed valve in suction and / or
discharge pipe is not permitted!
There´s a danger, that high surface
temperatures are developing at th
e pump
casing after relatively short time, through fast
heating of the liquid inside the pump.
Fast pressure increase inside the pump can
lead to overload and, thus, the pump can burst.
In chapter 6.4.1 the minimum flow is stated. Longer
operating phases with these flows and the named
liquids don´t cause additional increase of surface
temperature at the pump.
Furthermore the references in chapter 6 of these
operating Instructions must be taken into
consideration.
On pumps with mech. seals the perm
itted
temperature limits can be exceeded due to dry-
run. Dry run not only can occur on insufficiently
filled seal casing, but also because of too much
gas in the medium.
Operation of the pump out of the permitted
operating range can lead to dry-run, as well.
2.7.5 Temperature limits
Under normal operating conditions the highest
temperatures must be expected at the surface
of the pump casing and in the area of the
bearings.
The surface temperature occurring at pump casing
corresponds with the temperature of the pumped
liquid.
In the area of lantern and motor free contact of
surface to environment must be given for proper
cooling.
During operation of the pump it must be
secu
red that an overabundant sedimentation of
dust is avoided (regular cleaning
), to prevent
heating of pump surface over the permitted
temperature.
The operator of the plant must secure that the
defined operating temperature is observed. The
max. allowed temperature of the pumped liquid at
suction depends on the particular temperature
class.
The following table shows the theoretical temperature
limits of the pumped liquid in consideration of the
temperature classes acc. to EN 13463-1.
Temperature class acc.
EN 13463-1
Temperature class acc.
EN 13463-1
T4 (135°C) 135°C
T3 (200°C) 140°C
T2 (300°C) 140°C
T1 (450°C) 140°C
The particular allowed operating temperature of
the pump is shown in the data sheet and / or the
order confirmation resp. the type plate at the
pump.
2.7.6 Maintenance
For a secure and reliable operat
ion it must be
secured by regular inspections, that the unit is
maintained competently and is kept in good
technical condition.
Example: Function of bearings. Operation and
application conditions are essentially responsible for
their achievable life cycle.
By regular control of the lubricant and the running
sound the danger of occurring over temperatures by
bearings running hot or defect bearing seals is
avoided. Refer to chapter 6.6 and 7.4.
The function of the shaft sealing must be secured by
regular control.
If auxiliary systems (e.g. external flushing, cooling,
heating) are installed, it must be checked, if monitoring
devices are necessary to secure the function.

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 6 Revision 02
Article No 771076102 Issue 01/2010
2.7.7 Electric switches and control device,
Instrumentation and accessories
Electri
c switches and control devices,
instru
mentation and accessories must
correspond with the valid safety requirements
and regulations for explosion protection.
2.8 Use acc. to Regulations
2.8.1 Speed, Pressure, Temperature
Suitable safety measures must
be taken at the
plant to ensure that the speed, pressure and
temperature of the pump and the shaft sealing
do not exceed the limit values given in the data
sheet and / or order confirmation. The given
admission pressures (system pressures) must
also be sufficiently high.
Further, pressure shocks, as can occur on too fast
shut down of the facility, must be kept away from the
pump (e.g. by non-return valve at pressure side,
airtanks). Quick temperature changes must be
avoided. They could cause a temperature shock and
lead to damage or impair the function of single
components.
2.8.2 Permitted Nozzle Loads and Torques
Basically the suction and discharge piping must
be designed in such way, that as little forces as
possible are effective to the pump. If tha
t is not
possible, the values shown in chapter 3.5 must
not be exceeded under any circumstances. This
is valid for the operation as well as for the
standstill of the pump and therefore for all
pos
sible pressures and temperatures of the
unit.
2.8.3 NPSH
The pumped liquid must have a min. pressure
NPSH at the impeller inlet, so that cavitation
free work is secured resp. a "break off" of the
pump flow is prevented. This condition is
fulfilled, when NPSH-
value of the system
(NPSHA) lies above NPSH-value of
the pump
(NPSHR) under all operating conditions.
Attentention must especially be piad to the NPSH-
value on pumping liquids near the vapour pressure. If
the NPSH-value of the pump remains under, this can
lead from damage of the material due to cavitation to
destruction by overheating.
The NPSH-value of the pump (NPSHR) is shown in
the curves of every pump type.
2.8.4 Sealing, Flushing, Cooling
Suitable provisions for the regulation and monitoring of
sealing, flushing or cooling are to be provided.
When handling dangerous liquids or if temperatures
are high, care should be taken to ensure that the
pump ceases operating if the sealing, flushing or
cooling system fails.
Sealing, flushing and cooling systems must always be
operational before the pump is started up. They
should not be taken out of operation until the pump
has stopped, provided that the nature of the operation
allows this at all.
2.8.5 Back Flow
In systems where pumps are operating in closed
circuits under pressure (gas cushions, steam
pressure), the pressure of the gas cushion must not
be reduced via the pump, since the back flow speed
may be much higher than the operating speed, which
would destroy the unit.
3. Description
3.1 Design
ICB-pumps are single-stage volute casing pumps in
block design. Hydraulic design and dimensions comply
with ISO 2858/ EN 22858, the technical design
complies with ISO 5199/EN 25199.
The motors comply with DIN 42677-IM B5. Motor and
pump shaft are coupled rigidly.
The permitted application conditions and design
details of the delivered pump are shown in the
attached data sheet and / or the order confirmation
(see Design Coding System in chapter 3.2).
Installation position: ICB-pump are intended for use
with horizontal shaft, discharge up. Installation
positions deviating therefrom must be approved by the
manufacturer.
3.1.1 Design Coding System
Due to the coding on data sheet and / or order
confirmation all information regarding the delivered
pump can be found in this Installation, Operation and
Maintenance Instruction, e.g.:
ICB 100 - 65 - 250 S1 V L 2 - 132
(0) (1) (2) (3) (4)
(5) (6) (7) (8)
Position (0) - Name of Model
ICB - ISO block pump
Position (1) - Suction Nozzle in mm
Position (2) - Discharge Nozzle in mm
Position (3) - Nominal diameter of impeller in mm
Position (4) - Shaft sealing
S1 - Single-mech. seal acc. DIN 24960 l1k /
EN 12756 form U
S4 - Single-mech. seal acc. DIN 24960 l1k /
EN 12756 form U
with Quench (throttle bush)
Position (5) - Material Impeller
N = Cast Iron (0.6025)
L = Ductile Iron (0.7043)
V = Carbon Steel (1.4408)
W = Duplex (1.4517)

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 7 Revision 02
Article No 771076102 Issue 01/2010
Position (6) - Material pump casing (same coding as
impeller, cast iron not available)
Position (7) - Stub shaft
2 - without shaft sleeve (Duplex 1.4462 std)
Position (8) - IEC Motor size
3.2 Shaft Sealing
Pumps of design ICB are exclusively sealed with
single mech. seals with installation dimensions acc. to
EN 12756 (DIN 24960), design "K", form "U".
Two shaft sealing variants are available. On the data
sheet and / or the order confirmation the kind of shaft
sealing is given. An instruction for the mounting and
operation of mech. seals is contained in the particular
"Mounting Instruction of Shaft Sealing".
For nominal size (d
1
) of the mech. seal refer to
following chart.
Type
nom. size
d
1
of mech.
seal
Type
nom. size
d
1
of mech.
seal
40-25-160 33
100-65-160 43
40-25-200 33
100-65-200 43
40-25-250 43
100-65-250 43
50-32-160 33
100-65-315 53
50-32-200 33
125-80-160 43
50-32-250 43
125-80-200 43
50-32-315 43
125-80-250 43
65-40-160 33
125-80-315 53
65-40-200 33
125-100-200 43
65-40-250 43
125-100-250 53
65-40-315 43
125-100-315 53
80-50-160 33
150-125-250 53
80-50-200 33
150-125-315 53
80-50-250 43
200-150-250 53
80-50-315 43
The
mech. seal used in the standard design is
not resistant to mineral oils.
For further details about mech. seals, as well as
the dangers of accidents, connected to them
refer to chapter 6.6 and chapter 7.2.
3.3 Bearing
The shaft is guided by the ball bearings of the motor.
The bearings are grease lubricated for life and,
therefore maintenance-free.
3.4 Approximate Value for Sound
Pressure Level
Sound pressure level L
pA
in dB(A)
Pump alone Pump + Motor
Nominal
power
P
N
in kW
2950
min
-1
1450
min
-1
975
min
-1
2950
min
-1
1450
min
-1
975
min
-1
0,55 50,5 49,5 49,0 58,0 52,0 51,5
0,75 52,0 51,0 50,5 59,0 54,0 53,0
1,1 54,0 53,0 52,5 60,0 55,5 54,5
1,5 55,5 55,0 54,5 63,5 57,0 56,0
2,2 58,0 57,0 56,5 64,5 59,0 58,5
3,0 59,5 58,5 58,0 68,5 61,0 62,0
4,0 61,0 60,0 59,5 69,0 63,0 63,0
5,5 63,0 62,0 61,5 70,0 65,0 65,0
7,5 64,5 63,5 63,0 70,5 67,0 67,0
11,0 66,5 65,5 65,0 72,0 69,0 68,5
15,0 68,0 67,0 66,5 72,5 70,0 70,5
18,5 69,0 68,5 68,0 73,0 70,5 74,0
22,0 70,5 69,5 69,0 74,5 71,0 74,0
30,0 72,0 71,0 - 75,0 72,0 -
37,0 73,0 - - 76,0 - -
Sound pressure level L
pA
measured in 1 m distance
from pump surface acc. to DIN 45635, part 1 and 24.
Room and foundation influences are not considered.
The tolerance for these values is ±3 dB(A).
Addition with 60 Hz-operation:
Pump alone: −
Pump with motor: +4 dB(A)
3.5 Permitted Nozzle Loads and Torques
at the Pump Nozzles ...
... following the Europump-Recommendation for
pump acc. to ISO 5199.
The data for forces and torques are only valid for static
piping loads.
All values for forces and torques refer to standard
materials EN-GJS400-18LT and 1.4408.
pic 1

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 8 Revision 02
Article No 771076102 Issue 01/2010
Suction nozzle Discharge nozzle
Forces in N Torques in Nm Forces in N Torques in NmSizes ∅DN
Fx Fy Fz ∑F Mx My Mz ∑M ∅DN
Fx Fy Fz ∑F Mx My Mz ∑M
40-25-160 40 700 620 560 1100
730 500 590 1070
25 420 400 480 730 500 340 400 730
40-25-200 40 700 620 560 1100
730 500 590 1070
25 420 400 480 730 500 340 400 730
40-25-250 40 700 620 560 1100
730 500 590 1070
25 420 400 480 730 500 340 400 730
50-32-160 50 920 840 760 1450
780 560 650 1150
32 500 480 590 930 620 420 480 900
50-32-200 50 920 840 760 1450
780 560 650 1150
32 500 480 590 930 620 420 480 900
50-32-250 50 920 840 760 1450
780 560 650 1150
32 500 480 590 930 620 420 480 900
50-32-315 50 920 840 760 1450
780 560 650 1150
32 500 480 590 930 620 420 480 900
65-40-160 65 1180
1040
950 1850
840 620 670 1230
40 620 560 700 1100
730 500 590 1060
65-40-200 65 1180
1040
950 1850
840 620 670 1230
40 620 560 700 1100
730 500 590 1060
65-40-250 65 1180
1040
950 1850
840 620 670 1230
40 620 560 700 1100
730 500 590 1060
65-40-315 65 1180
1040
950 1850
840 620 670 1230
40 620 560 700 1100
730 500 590 1060
80-50-160 80 1400
1260
1150
2200
900 650 730 1320
50 840 760 920 1450
780 560 650 1150
80-50-200 80 1400
1260
1150
2200
900 650 730 1320
50 840 760 920 1450
780 560 650 1150
80-50-250 80 1400
1260
1150
2200
900 650 730 1320
50 840 760 920 1450
780 560 650 1150
80-50-315 80 1400
1260
1150
2200
900 650 730 1320
50 840 760 920 1450
780 560 650 1150
100-65-160
100 1880
1680
1520
2950
980 700 810 1450
65 1040
950 1180
1850
840 620 670 1230
100-65-200
100 1880
1680
1520
2950
980 700 810 1450
65 1040
950 1180
1850
840 620 670 1230
100-65-250
100 1880
1680
1520
2950
980 700 810 1450
65 1040
950 1180
1850
840 620 670 1230
100-65-315
100 1880
1680
1520
2950
980 700 810 1450
65 1040
950 1180
1850
840 620 670 1230
125-80-160
125 2210
2000
1800
3480
1180
840 1070
1710
80 1260
1150
1400
2200
900 650 730 1320
125-80-200
125 2210
2000
1800
3480
1180
840 1070
1710
80 1260
1150
1400
2200
900 650 730 1320
125-80-250
125 2210
2000
1800
3480
1180
840 1070
1710
80 1260
1150
1400
2200
900 650 730 1320
125-80-315
125 2210
2000
1800
3480
1180
840 1070
1710
80 1260
1150
1400
2200
900 650 730 1320
125-100-200
125 2210
2000
1800
3480
1180
840 1070
1710
100 1680
1520
1880
2950
980 700 810 1450
125-100-250
125 2210
2000
1800
3480
1180
840 1070
1710
100 1680
1520
1880
2950
980 700 810 1450
125-100-315
125 2210
2000
1800
3480
1180
840 1070
1710
100 1680
1520
1880
2950
980 700 810 1450
150-125-250
150 2800
2520
2270
4400
1400
980 1150
2050
125 2000
1800
2210
3480
1180
840 1070
1710
150-125-315
150 2800
2520
2270
4400
1400
980 1150
2050
125 2000
1800
2210
3480
1180
840 1070
1710
200-150-250
200 3750
3360
3030
5850
1820
1290
1490
2700
150 2520
2270
2800
4400
1400
980 1150
2050
3.6 Permitted pressures and temperatures
Basically the values, regarding pressures and
temperatures, given in the data sheet and / or the
order confirmation, as well as on the name plate.
Exceeding or remaining under of these values are
undue. If there are no pressures and / or temperatures
mentioned in data sheet and / or order confirmation,
the following limits are valid for suction pressure and
room temperature:
Suction pressure (System pressure) = Pressure at
pump suction: max. 5 bar
Ambient temperature max. 40°C.
On Application of pumps local laws and regulations
must be noticed, as well (e.g. DIN 4747 or DIN 4752,
section 4.5).
For all pump types, except:
50-32-315 - 65-40-315 - 80-50-315 - 100-65-315 -
125-80-315 - 125-100-315
Only for:
50-32-315 - 65-40-315 - 80-50-315 - 100-65-315 -
125-80-315 - 125-100-315
Curve
Casing material Description
A 1.4408 Austenitic Steel
B 1.4517 Duplex Steel
C EN-GJS-400-18-LT
(0.7043) Ductile Iron
The given pressure and temperature limits are valid
for standard mech. seals.
Application limits for other materials on request.

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 9 Revision 02
Article No 771076102 Issue 01/2010
3.7 Condensate
On motors which are subject to strong temperature
deviations or extreme climatic conditions, we
recommend the use of a motor with stand-by heating
to avoid formation of condensate inside the motor.
The stand-by heating must not be switched on during
the operation of the motor.
4. Transport, Handling, Storage
4.1 Transport, Handling
Check the pump / pump unit immediately upon
delivery / receipt of despatch for damage or
missing parts.
The pump / pump unit must be transported
carefully and by competent personnel. Avoid
serious impacts.
Keep the pump / pump unit in the same position in
which it was supplied from the factory. Take note
of the instructions on the packaging.
The suction and discharge side of the pump must
be closed with plugs during transport and storage.
Dispose of all packing materials in accordance
with local regulations.
Lifting devices (e.g. fork-lift truck, crane, crane
device, pulleys, sling ropes, etc.) must be
sufficiently strong and must only be used by
authorized persons.
The pump / pump unit may only be lifted by solid
points such as the casing, flanges or frame.
Picture 2 shows the correct method of carrying by
crane.
Do not stand underneath suspended loads.
Take note of the general regulations on
prevention of accidents.
The pump / pump unit must be secured against
tipping over and slipping until
it has been fixed
in its final location.
Sling ropes must not be fixed to ends of shafts
or the ring loops of the motor.
Slipping out of the pump / unit of the transport
lifting device can cause damages to persons
and things.
pic 2
4.2 Storage / Conservation
Pumps or units, which are stored over a longer period
before start-up (max. 6 months), must be protected
from moisture, vibrations and dirt (e.g. by wrapping in
oil paper or plastic). Pumps must basically be stored in
a place where they are protected from the weather,
e.g. under dry cover. During this time, all suction and
discharge branches and all other intakes and outlets
must be closed with dummy flanges or plugs.
For longer periods of storage conservation
measurements at machined surfaces and packing with
moisture protection can be necessary!
5. Mounting / Installation
5.1 Mounting of Pump / Unit
The pumps must be bolted to a solid base (e.g.
concrete foundation, steel plate, steel bracket, etc.).
This base must withstand all loads occurring during
operation. The place, where the pump is mounted
must be prepared acc. to the dimensions of the
dimensional drawings. The concrete foundations
should have sufficient firmness acc. to DIN 1045 or
equal standard (min. BN 15), to ensure a secure,
functional mounting. The concrete foundation must
have set, before the unit is erected. Its surface must
be horizontal and even. For the position and size of
the pump feet and the foundation screws refer to the
dimensional drawing.
Concrete expansion bolts, epoxy capsule anchor bolts
or anchor bolts grouted with the foundation (stone
screws), can be used for.
Sufficient space must be provided for
mainte
nance and repair work, especially for
replacing the drive motor or the com
plete pump
unit. The motor fan must be able to take in
enough cool air, and the intake grille must
therefore be at least 10 cm away from any wall,
etc.
When mounting the pump on the foundation it
must be adjusted at the discharge nozzle by
means of a spirit-level (at discharge nozzle). The
permitted deviation is 0,2 mm/m. Levelling shims

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 10 Revision 02
Article No 771076102 Issue 01/2010
must be inserted next to the foundation anchors
and must lie plainly.
If vibrations are transmitted to the foundation from
adjoining components, it must be guarded through
adequate vibration damping paddings (vibrations
from outside can impair the bearing).
To prevent vibrations being transmitted to
adjoining components, the foundation should be
laid on a suitable insulating base.
The size of these insulating pads will
vary,
de
pending on circumstances, and should
there
fore be determined by an experienced
specialist.
5.2 Connection of Pipings to the Pump
The pump must not be used as fixed point for
the piping. The permitted piping loads must not
be exceeded, refer to chapter 3.5.
5.2.1 Suction and discharge pipe
The pipes must be of a size and design that liquid
can flow freely into the pump and that the pump
functions without problems. Particular attention is
to be paid to ensuring that suction pipes are
airtight and that the NPSH values are observed.
Under suction lift condition lay the suction pipe in
the horizontal section towards the pump so that it
is slightly inclined upwards so that no air traps
occur. Do not install fittings or elbows right before
the suction nozzle.
If the suction supply is under vacuum and
entrained gas may be present in the liquid, it is
recommended that a vent line (min. diameter 25
mm) be considered upstream of the pump suction
with return to the suction supply, above the max
liquid level.
An additional flushed piping - discharge branch-
vent line - makes it easier to de-aerate the pump
before start-up (pic 3).
pic 3
When laying the pipes, make sure that the pump
is accessible for maintenance, installation and
disassembly.
Notice "Permitted Forces on Flanges" (chapter
3.7).
If expansion joints are used in the pipes, they
have to be supported in such a way that the pump
is not loaded unduly high because of the pressure
in the pipes.
Before connecting up to pump: remove protective
coverings from suction and discharge branches.
Before starting up, the pipe system, fittings and
equipment must be cleaned to remove weld
spatter, scale etc. Any pollutants are to be
completely removed from pump units that are
directly or indirectly connected to drinking water
systems before being installed and taken into use.
To protect the shaft sealing (especially mechanical
seals) against foreign impurities, it is
recommended that a sieve, 800 micron, is
installed in the suction / intake pipe when the
motor is being started up.
If the pipe system is tested with the pump
installed, do not exceed the maximum permitted
casing pressure of the pump and/or shaft sealing
(see data sheet).
When emptying the pipe after the pressure test,
make sure that the pump is treated properly
(danger of rust and problems when starting up).
5.2.2 Additional connections
Any required sealing, flushing or cooling pipe
connections must be installed. Please consult the data
sheet to see which pipes, pressures and amounts are
necessary. The position and size of connections to the
pump are given in the appendix, "Connections".
These connections are essential for the
function!
It is recommended that a pipeline is installed to take
off any leakage from the shaft seal. For connection,
see appendix, "Connections".
5.3 Drive
Note the Operating Instructions of the motor
manufacturer.
On application in zone 1 and 2 a motor with
valid Atex-certification must be used.
If in the process of the repair a new motor is used , the
following has to be noticed:
The motor must comply with the requirements
stated in sheet 1220.1A608 (order from
manufacturer, on demand).
Clean motor end and motor flange of new motor
carefully (remove varnish).
5.4 Electric Connection
Elec
trical connection work may only be carried
out by an authorised professional. The rules
and regulations valid for electrical technology,
especially those concerned with safety
meas
ures, must be observed. The regulations
of the national power supply compani
es
operating in that area must also be observed.
Before starting work, check that the information on the
motor name plate is the same as the local mains
network. The power supply cable of the coupled drive

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 11 Revision 02
Article No 771076102 Issue 01/2010
motor must be connected up in accordance with the
wiring diagram produced by the motor manufacturer.
A protective motor switch must be provided.
In areas endangered to explosion IEC 60079-
14
must additionally be noticed for the electric
installation.
The direction of rotation must only be checked
when the pump is full. Dry running will cause
damage to the pump.
5.5 Final Control
It must be possible to turn the unit easily by hand at
the stub shaft.
6. Start-up, Operation, Shut down
The plant may only be started up by people who
are familiar
with the local safety regulations and
with these Operating Instructions (especially
with the safety regulations and safety
instructions given here).
6.1 Initial start-up
Before starting up the pump, check, if the following
points were controlled and carried out:
There´s no need to lubricate the pump before
starting it up.
Pump and suction pipe must be filled completely
with liquid when starting up.
Turn pump unit once again by hand and check
that it moves smoothly and evenly.
Check that lantern guard sheets are mounted and
that all safety devices are operational.
Switch on any existing sealing or flushing pipings.
For quantities and pressures refer to data sheet
and / or order confirmation.
Open valve in suction /intake pipe.
Set discharge side valve to approx. 25% of rated
flow quantity. With pumps with a discharge branch
rated width less than 200, the valve can remain
closed when starting up.
Secure, that unit is electrically connected acc. to
all regulations and with all safety devices.
Check direction of rotation by switching on and off
briefly. It must be the same as the directional
arrow on the drive lantern.
6.2 Switch on drive
Immediately (max. 10 seconds on 50 Hz resp.
max. 7 seconds on 60 Hz currency feed) after
reaching normal operating speed open discharge
valve adjust the required operating point. The
pumping data shown at the type plate resp. in the
data sheet and / or the order confirmation must be
met. Every change is only permitted after talking
with the manufacturer!
Operation with clos
ed valve in the suction and /
or discharge piping is not permitted.
On starting-up without back-pressure, the back-
pressure must be produced through throttling at
the discharge side. After reaching full back-
pressure open valve.
If pump does no
t reach attended head or if
atypical sounds or vibrations do occur:
Switch off pump (see chapter 6.7) and seek for
causes (see chapter 10).
6.3 Restarting
Basically, the same procedure should be followed as
for starting up for the first time. However, there is no
need to check the direction of rotation and the
accessibility of the pump unit.
The pump should only be automatically restarted if it
has been made sure that the pump has remained
filled whilst stand by.
Be particularly careful not to touch ho
t machine
parts and when working in the unprotected shaft
seal area. Remember that automatically
con
trolled systems may switch themselves on
suddenly at any time.
Suitable warning signs
should be affixed.
6.4 Limits of Operation
The operating limits of
the pump / unit regarding
pressure, temperature, performance and speed
are shown in the data sheet and / or order
con
firmation and must be observed under any
circumstances!
Do not exceed the output given on the motor
name plate.
Avoid sudden changes in temperature
(temperature shocks).
The pump and motor should run evenly and
without vibrations; check at least once a week.
6.4.1 Flow min. / max.
If no other data are given in the curves or data sheets,
the following is valid:
Q
min
= 0,1 x Q
BEP
for for short time operation
Q
min
= 0,3 x Q
BEP
for continuous operation
Q
max
= 1,2 x Q
BEP
for continuous operation *)
Q
BEP
= Flow in efficiency optimum
*) on condition that NPSH
facility
> (NPSH
pump
+ 0,5 m)

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 12 Revision 02
Article No 771076102 Issue 01/2010
6.4.2 Abrasive Media
On pumping liquids with ab
rasive components
an increased wear at hydraulic and shaft sea
ling
must be expected. The intervals of inspec
tion
should be reduced compared to the usual
times.
6.4.3 Permitted number of starts
The permitted number of starts of the pump must not
be exceeded, see diagram 6.
1,0
10,0
100,0
1 10 100 1000
Motor power [kW]
max. perm. starts/h
diagram 6
With electric motors, the permitted number of starts is
given in the attached motor operating instructions.
If two different figures are given, the lower figure is
valid.
6.5 Lubrication
The pump has no bearings and, therefore there´s no
need for lubrication.
For possibly required lubrication of the motor bearings
refer to the Operation and Maintenance Instructions of
the motor supplier.
6.6 Monitoring
In areas endang
ered to explosion it is
recom
mended to monitor the temperature of the
bearings and the vibrations of the pump.
Regular monitoring and maintenance will ex
tend
the life of your pump or pump system.
Check pump for leaks at least once a week.
Check the regulating and monitoring devices of
any sealing or flushing systems once a week to
ensure that they function properly. Outgoing
cooling water should be handwarm.
Pumps which are exposed to corrosive chemicals
or to wear through abrasion must be inspected
periodically for corrosion or wear and tear. The
first inspection should be carried out after six
months. All further inspection intervals should be
determined on the basis of the state of the pump.
6.7 Shutting down
Close the valve in discharge pipe right before
(max. 10 seconds) switching off the motor. This is
not necessary if there is a spring-loaded check
valve.
Switch off motor (make sure it runs down quietly).
Close the valve on suction side.
Close auxiliary circuit.
On danger of freezing empty pump and pipes
completely.
If pump remains under pressure and temperature
when stationary: leave existing sealing and
flushing systems switched on.
The shaft sealing must remain sealed if there is a
risk of air being sucked in (in the event of supply
from vacuum systems or parallel operation with
shared suction pipe).
6.8 Storage / longer periods of non-
operation
6.8.1 Storage of new pumps
If the putting into operation shall happen a longer
period after the delivery, we recommend the following
measures for the storage of the pump:
Store pump at a dry place.
Rotate pump by hand at least once a month.
6.8.2 Measures for longer putting out of operation
Pump remains installed and in ready for operation:
Test runs of 5 min. duration must be made in
regular intervals. The span between the test runs
is depending on the plant. However, it should be
made once a week, at least.
6.8.3 Longer periods of non-operation
Start-up must be handled like initial start-up (see
chapter 6).
a) Filled pumps
Switch stand-by pumps on and immediately off
again once a week. Possibly use as main pump.
If the stand-by pump is under pressure and
temperature: leave all existing sealing and flushing
systems swiched on.
Replace motor bearings after 5 years.
b) Drained pumps
Turn shaft at least 1x week (do not switch on
because of dry running).
Replace motor bearings after 5 years.

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 13 Revision 02
Article No 771076102 Issue 01/2010
7. Servicing, Maintenance
7.1 General remarks
Work should only be carried out on the pump or
pump unit when it is not in operation.
You must
observe chapter 2.
Maintenance and servicing work must only be
carried out by trained, experienced staff who
are familiar with the contents of these Operating
Instructions, or by the Manufacturer's own
service staff.
7.2 Mechanical seals
Before opening the p
ump, it is essential that you
note chapter 2 and chapter 8.
If the liquid being handled leaks out at the mechanical
seal, it is damaged and must be replaced.
Replacement of the mech. seal according to
accompanying "Mounting Instructions for Shaft
sealing".
7.3 Motor bearings
After approx. 5 years the grease in the motor bearings
is so aged, that a replacement of the bearings is
recommended. However, the bearings must be
replaced after 25000 operating hours, at least, resp.
acc. to the Maintenance Instruction of the motor
supplier, if that recommends a shorter maintenance
period.
7.4 Cleaning of pump
Dirt on the outside of the pump has an adverse
effect on transmission of heat. The pump should
therefore be cleaned with water at regular
intervals (depending on the degree of dirt).
The pump must not be cleaned with pressuri
sed
water - water will get into the bearings.
8. Dismantling and repair of pump
8.1 General remarks
Repair to the pump or pump system may only
be carried out by authorised s
killed personnel or
by the manufacturer´s specialist staff.
When disassembling the pump pay attention to
chapter 2 and chapter 4.1.
For mounting and repair you can order specialized
personnel if you want.
If dangerous liquids are pumped the approp
riate
disposal of the handled liquid is necessary
befo
re 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 ob
served,
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 n
o
danger of setting fire, cause an explosion or
cause injurious vapours.
Use original spare parts only. Pay attention to
the right materials and the matching design.
8.2 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.
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.
8.3 Removal and Installation of screen in
the motor lantern
The guard plates (680) are fixed in the windows of the
motor lantern (681).
For removing insert a screwdriver about 4 cm into the
last row with punches of the guard plate. Then pull up
the screwdriver until the lower edge of the guard plate
lifts off the window. Now you can remove the
screwdriver together with the guard plate from the
window (see picture 8).
On installation insert the screwdriver about 4 cm into
the last row with punches of the guard plate. Then put
the upper part of the guard plate into the upper edge
of the window. Now pull up the screw driver until the
guard plate is bent through so much, that it can be
inserted into the lower edge of the window of the
motor lantern.

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 14 Revision 02
Article No 771076102 Issue 01/2010
pic 8
Pull up screw driver only so far as is absolutely
necessary to insert the guard plate into the
window. If the guard plate doesn´t stick fast in
the window after installation:
Dismantle g
uard plate once again, flatten it and
install again.
8.4 Removal of the Back Pull Out
Assembly
The back pull out assembly consists of all pump parts
except the volute casing (102V). As the pumps are
constructed in block design, the volute casing (102V)
can remain on the foundation and in the piping, if it´s
not the volute casing itself, which must be repaired.
Drain volute casing (102V) via drain plug (912.11).
Loosen screws of existing sealing or flushing
pipings.
Loosen screws of support food (183) from the
foundation (not existing on all sizes).
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 9 for lifting recommendations.
pic 9
Loosen hexagen head bolt (901.11) from the
casing.
Using the jack screws provided (901.42), separate
the Back Pull Out Assembly from the casing.
8.5 Removal of Impeller
Notice attached "Mounting Instruction for Shaft
Sealing".
If the impeller has back vanes check the axial
clearance "a" between the impeller (230) and
casing cover (161) before you continue the
dismounting. Refer to sect. 8.8.1.
Loosen impeller nut with a sensitive hit on the
wrench (right-hand thread). If necessary back up
with a pry bar in the cross boring of the stud shaft
(in clamp area).
Draw off the impeller (230) with two screw drivers
or pry bars (picture 10). Remove key (940.31).
Be sure to locate pry bars under impeller vanes
to prevent damage to the impeller.
For further dismounting, and for installation, the
Back Pull Out Assembly should be placed in a
vertical position. Prevent assembly from tipping!
pic 10
8.6 Removal of Shaft Sealing
Before you remove casing cover notice "Mounting
Instructions for Shaft Sealing".
Unfasten hexagonal nut (902.32) (not available on
all pump sizes) and take casing cover (161) out of
bearing bracket (344).
8.7 Removal of Stub Shaft
Loosen screws (920.41) and pull motor with stub
shaft (210) out of the motor lantern (341).
Loosen radial stub shaft screwing (904.41 and
904.42) (stud bolts) and deduct stub shaft (210)
from motor shaft. For support (break loose) you
can insert a solid screw driver into the cross
boring, press it against the front face of the motor
and move both shafts against each other.

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 15 Revision 02
Article No 771076102 Issue 01/2010
8.8 Reconditioning
After disassembly all parts must be cleaned and
checked for wear carefully. Worn or damaged parts
must be replaced by new parts (spare parts).
It is recommended in most cases to replace mech.
seal, ball bearings and seals (flat seal, O-rings).
All PTFE-
sealing elements and graphite
sealings are intended for being used only once.
In most cases it make sense, if damaged absolutely
necessary, to renew the mech. seal and the bearings
Deposits on the impeller (230), in the volute casing
(102V) or on the casing cover must be removed.
8.8.1 Clearance at impeller
Suction side of impeller Back vanes of impeller
Drive side of impeller
Only with pump size
100-65-315
125-80-315
125-100-315
150-125-315
Nominal diameter D (mm) 60
68 85
100
120
135
155
175 220
min.
0,15
0,17
0,20
0,22
0,25
new max.
0,19
0,22
0,24
0,27
0,30
Radial
clearance
s (mm) worn 0,78
0,85
0,90
1,05
1,15
new 0,8 - 1,2Axial
clearance
a (mm) worn max. 1,7
When the wea
r limits has been reached or
exceeded, the worn parts must be replaced.
For volute casings (102V) with a wear ring (502.11)
and cover casings (161) with a wear ring (502.31)
there are the following possibilities to restore the
correct clearance:
a) Renew impeller (230) and wear ring. Then the
original measures are restored.
b) A customized wear ring (bored to fit) can be
supplied to avoid replacement of the impeller.
Please contact factory for details.
When volute casing (102V) or casing cover (161)
without wear ring must be repaired, a wear ring can be
installed to renew pump performance. Remachining of
the volute casing and / or casing cover is required.
Please contact the factory for details and assistance.
8.9 Mounting
8.9.1 General
Re-assemble the pumps using the reverse order of
steps as completed for pump disassembly. However
the following observations should be considered:
Pay attention to the utmost cleanliness when
reassembling the pump.
For tight tolerances e.g. between stub shaft (210)
and motor shaft or impeller (230) and shaft (210),
as well as thread, use suitable anti-galling
compound (e.g. Molykote / Never-Seeze), so that
the next mounting and dismounting will be easier.
Anti-
galling compound must be compatible with
the pumpage.
Screws should be tightened, with the following
torque:
Screw torque in Nm
Location Screw
Size Lubricated
threads Dry threads
M12 35 50
M16 105 150
Casing Screws
M20 210 305
M10 35 50
M12 60 90
All other scres
M16 150 220
Do not use excessive force.
For mounting of stub shaft refer to chapter 8.9.2.
For mounting of mech. seal refer to separate
"Mounting Instruction of Shaft Sealing" and
chapter 8.5.
For impellers with back vanes the axial clearance
between the back vanes and the casing cover
(161) should be checked after mounting the
impeller (230) and tightening the impeller nut (922)
(see chapter 8.8.1).
After the mounting of the back pull out assembly,
and its assembly into the volute casing, turn the
shaft and control the free moving of the pump in
this way. The shaft sealings will cause slightly
resistance when turning, but there must not be
any contact between metal parts.
Before starting the pump do not forget to install
and connect all security devices.
8.9.2 Mounting of Stub Shaft
Insert key in the motor stump.
Put anti-galling compound onto the motor stump
(see point 8.9.1).
Push stub shaft up the motor shaft to measure A
(see pict. 11 and chart).
Drill countersink into motorshaft, appr. 2-3 mm
depth, through the radial bore in the motor shaft
(see pict. 11), by useing a twistdrill with 90°tip.
Remove cuttings out of the stud hole (e.g. with
compressed-air), screw in and make safe thread
pins (904.41 and 904.42) (e.g. with Omnifit 100 M
or Loctite).
Check smooth running of stub shaft opposite to
motor flange with a dial gauge. The pointer
deflection of the dial gauge must not exceed 0,1
mm.

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 16 Revision 02
Article No 771076102 Issue 01/2010
pic 11
Measure A by motor size
Type 80 90 100
112
132
160
180
200
40-25-160 157
157
197
197
197
232
- -
40-25-200 157
157
197
197
197
232
- -
40-25-250 162
162
202
202
202
237
237
237
50-32-160 157
157
197
197
197
232
- -
50-32-200 157
157
197
197
197
232
- -
50-32-250 162
162
202
202
202
237
237
237
50-32-315 - - 202
202
197
237
237
237
65-40-160 157
157
197
197
197
232
- -
65-40-200 157
157
197
197
197
232
232
-
65-40-250 162
162
202
202
202
237
237
237
65-40-315 - - 202
202
197
237
237
237
80-50-160 157
157
197
197
197
232
232
-
80-50-200 157
157
197
197
202
232
232
232
80-50-250 - 162
202
202
202
237
237
237
80-50-315 - - 202
202
202
237
237
237
100-65-160 162
162
202
202
202
237
237
237
100-65-200 - 162
202
202
202
237
237
237
100-65-250 - 162
202
202
206
237
237
237
100-65-315 - - 206
206
202
241
241
241
125-80-160 - 162
202
202
202
237
237
237
125-80-200 - 162
202
202
202
237
237
237
125-80-250 - - 202
202
202
237
237
237
125-80-315 - - - 206
206
241
241
241
125-100-200 - - 202
202
202
237
237
237
125-100-250 - - 216
216
216
251
251
251
125-100-315 - - - - 206
241
241
241
150-125-250 - - - - 216
251
251
251
150-125-315 - - - - - 241
241
241
200-150-250 - - - - - 251
251
251
9. Spare parts, Spare pumps
9.1 Spare parts
Spare parts should be selected to last for two-years
continuous operation. If no other guidelines are
applicable, we recommend that you stock the number
of parts listed below (in accordance with VDMA
24296).
To ensure optimum availability, we recommend
that suitable quantities of spare parts are held in
stock, es
pecially if these are made from special
materials and in the case of mechanical se
als,
because of the longer delivery times.
Number of pumps (incl. stand-by pumps)
2 3 4 5 6/7 8/9 10/+
Spare Parts Number of spare parts
Impeller 1 1 1 2 2 2 20%
Wear ring 2 2 2 3 3 4 50%
Shaft with keys and nuts
1 1 1 2 2 2 20%
Joints for pump casing
sets
4 6 8 8 9 12 150%
other joints
sets
4 6 8 8 9 10 100%
Mech. seal
sets
1 1 2 2 2 3 25%
Ordering spare parts
When ordering spare parts, please supply the
following information:
Type: ______________________________________________________________________
S/N (Order No.) _____________________________________________________
Part name ______________________________________________________________
Sectional drawing ___________________________________________________
All the information is given in the data sheet and the
relevant sectional drawing.
Store spare parts in dry and clean rooms.
9.2 Stand-by pumps
It is essential that a sufficient number of stand-
by pumps are kept ready for use in plants where
failure of a pump could endanger human life or
cause damage to property or hig
h costs.
Regular checks should be carried out to ensure
that such pumps are always ready for use (see
Point 6.8).
Store stand-by pumps according to point 6.8.

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 17 Revision 02
Article No 771076102 Issue 01/2010
10. Faults - Causes and Solutions
The following notes on causes of faults and how to
repair them are intended as an aid to recognising the
problem. The manufacturer's Customer Service
Department is available to help repair faults that the
operator cannot or does not want to repair. If the
operator repairs or changes the pump, the design data
on the data sheet and chapter 2 of these Operating
Instructions should be particularly taken into account.
If necessary, the written agreement of the
manufacturer must be obtained.
Discharge too low Discharge stops after a time Head too low Head too high Drive mechanism overloaded Pump not running quietly Temperature in pump too high Temperature in shaft sealing too high Temperature at the bearing too high Pump leaking Leakage rate at shaft sealing too high
Cause Solution
■Back-pressure too high
check facility for pollution, open discharge valve
reduce resistance in discharge pipe (e.g. clean filter if
necessary)
use larger impeller (note available motor power)
■■■Back-pressure too low, discharge too low throttle discharge valve
■■Speed too high reduce speed
compare speed of motor with specified pump speed (rating
plate)
when adjusting speed (frequency transformer) check reference
value setting
■■Speed too low increase speed (check available motor power)
compare speed of motor with specified pump speed (rating
plate)
when adjusting speed (frequency transformer) check reference
value settings
■■■■Flow too little increase min. flow (open discharge valve, bypass)
■Flow too big reduce flow (throttle discharge valve)
■■Impeller diameter too big use smaller impeller
■■Impeller diameter too small use larger impeller (check available motor power)
■■■■Pump and/or pipes not completely filled with liquid fill
vent
■■■Pump or suction/intake pipe blocked clean
■■Air pocket in pipeline vent
improve course of pipe
■■■■■Suction height too big / NPSH of system too small
increase liquid level and admission pressure
reduce resistance in the intake/suction pipe (change course
and rated width, open shut-off valves, clean filters)
■■■Air being sucked in increase liquid level
check if suction pipe is vacuum-tight
■■■Air being sucked in through shaft sealing clean sealing pipe
increase sealing pressure
replace shaft sealing
■■Direction of rotation is wrong swap over two phases of power supply (to be done by an
electrician)
■■■■Inner components suffering from wear replace worn parts
■■■Density and/or viscosity of liquid handled is too high seek assistance
■■Lines and roughness at shaft replace parts
■■Deposits on mechanical seal clean
replace mechanical seal if necessary
if necessary provide additional rinsing or quench
■■Impeller out of balance remove blocks/deposits
replace impeller if broken or unevenly worn
check shafts to ensure that they are running true
■■■■■Forces in pipeline too high (pump unit under strain) change (support pipes, use compensators, etc.)
is foundation plate/frame properly cast in place?
■Electricity supply not right (2-phase running) check voltage of all phases
check cable connections and fuses
■Sealing insufficient tighten screws
replace sealing
■■Bearing damaged replace
■Relief fittings insufficient clean relief openings in impeller
replace worn parts (impeller, split rings)
adjust in line with the system pressure/intake pressu
re given on
ordering
■System-related vibrations (resonance) seek assistance

Installation, Operation and Maintenance Instruction Model ICB
ICB 100-english page 18 Revision 02
Article No 771076102 Issue 01/2010
11. Motor Operating Instructions
The following instructions must be followed
exactly, to guarantee the safety at the
installation, at the operation and at the
ma
intenance of the motor. All persons should
be directed to the present manual which are
performing these tasks. The neglect of the
instructions can cause the loss of the
guarantee.
Electrical connections
Make sure that the rated voltage corresponds to
the supply voltage.
Ground the pump before making any other
connection.
We recommend that a high sensitivity
differential switch (30 mA) be installed as extra
protection against lethal electric shocks in the
event of faulty grounding.
Connect the pump to the mains using a multiple-pole
switch or other device ensuring multiple-pole
disconnection (interruption of all the supply wires) from
the mains, with a contact separation of at least 3 mm.
Remove the terminal board cover by first removing the
screws.
Carry out the connections as indicated on the back of
the terminal board cover, and as shown in fig. 3 - 4.
The single-phase version has a built-in overload
protection; the three-phase version must be equipped
by the user with a magneto-thermal switch or
magnetic starter with overload and undervoltage
protection, a thermal relay and fuses installed
upstream.
The overload relay must be set to the motor current
rating. The thermal relay may be set to a current value
slightly lower than the full load value when the electric
pump is definitely underloaded, but the thermal
overload protection must not be set to current values
higher than the full load values.
Checking the rotation direction of electric pumps
with three-phase motors.
The direction of rotation may be checked before the
pump is filled with the liquid to be pumped, provided
it is run for very short starts only.
The pump must not be run until it is filled with
liquid.
Continuous dry running will damage the
mechanical seal beyond repair.
If the direction of rotation is not anti-clockwise when
facing the pump from the suction side interchange two
supply leads.
Fault finding chart
PROBLEM PROBABLE CAUSE POSSIBLE
REMEDIES
1. The pump doesn’t
start
A) No electrical
power
B) Blown fuses:
B1 Because
inadeguate (blowing
current too low)
B2 Because the
motor or the supply
cable are damaged
C) Overload
protection previously
tripped
A) Supply electrical
power
B1 Replace fuses
with adequate ones
B2 Repair the motor
or replace the cable
C)Reset the
protection (if it trips
again see problem 2)
2. Overload
protection trips:
– accidentaly
A) Momentary loss of
a phase
– systematically C) Incorrect setting
of the motor switch
D) The pump’s
delivery is higher than
the rated one
E) Dense and viscous
liquid
C) Set to rated
current
D) Close the delivery
valve until the
capacity returns to
the rated value
E) Determine the
actual power
requirements and
replace the motor
accordingly