Kolmeks AE-20/4SC User manual

SC-INLINE DOMESTIC HOT WATER PUMPS - AEP, LP and ALP
1
243
04/2013 Subject to change without prior notice. www.kolmeks.com
AT_-1102/2 60Hz
Shaft power P2
kW A kg H
OKN-132 E1 F19 7.5 (9) 15.0 202 495
OKN-132 C1 F19 5.5 (6.6) 11.0 186 495
OKN-112 E1 F19 4.0 (4.8) 8.2 138 430
DN100 3600 r/min
H
645
min150
24
140 450
Ø133
Ø133
Ø133
Ø144
Ø144
Ø128
Ø144
Ø138
Ø128
Ø144 Ø138
Ø144
Ø128
Ø144
Ø138
Ø128
0
0 5
5
0 20
00 0
0 5
1
Ø128
100 5
0.1
10
0.2
15
0.3
20
0.4
25
0.5
30
0.6
35 40
0.7
l/s 0 5
0.1
10
0.2
15
0.3
20
0.4
25
0.5
30 35 40
0.6
l/s
1m/s
10
10
40
2m/s
15
15
60
3m/s
20
20
80
4m/s
150
Total efficiency
kW
8
2
107
110
2
4
6
NPSH
m
15
3
20
4
25
5
30
6
35
7
8
9
10
40
0
0 5
1
10
2
15
Flow
Total input power P1
Head
Pump efficiency
3
25
25
Nominal power inside the parenthesis available when motor is wound according to the supply voltage and frequency.
100
20
Ø180
8xØ19
Ø100
670
4
3xM12, Depth 16
G 1/4 G 1/4
4
25
5
30
6
35
7
8
9
40
10
l/s
kW
11
l/s
5m/s
30
30
120
35
140
m
3
/h
40
35
l/s
m
4xØ16
3xØ14
170
210
170
210
90
155
www.kolmeks.com
LOREM IPSUM JE ZULT
MAAR 60 HZ
PUMP SERVICE

PUMP SERVICE
9
244 04/2013 Subject to change without prior notice.
www.kolmeks..com
General notes
Kolmeks pumps do not require regular service. The pump shaft seal is a mechanical seal (not used in wet motor pumps). It
is a part which undergoes wear and which must be replaced if it starts to leak. Please note that a leakage of a few drops per
hour can be quite normal, especially when pumping water-glycol mixtures.
The pump motor bearings are pre-lubricated and can thus withstand several years of continuous use. In case of any motor
malfunction, we recommend replacing the whole motor unit.
Motor unit replacement
The pump motor unit includes: motor, sealing flange, impeller and seals.
If a motor malfunction or a seal leak occurs, replacing the motor unit is simple and quick and does not require long periods
of stand-by or operation downtime. There is no need to carry out procedures on the piping, because there is no need to
detach the pump housing.
Seal kits and O-rings for SC frequency converter pumps
Connection Grey cast Nodular Bronze Stainless Shaft seal, O-ring O-ring Motor
iron cast iron steel PN10
EN-GJL-200 EN-GJS-400 CuSn10Zn2 AISI 316 Ø [mm] Size Material
G or DN PN10 PN16 PN10 PN 16 materials [mm] [kW]
G 3/4 AE-20/4 SC_ no no no
12, carbon/
SiC Viton 123 X 2,5 NBR
0,08 and
0,2
AE-20/2 SC_ no no no
12, carbon/
SiC Viton 123 X 2,5 NBR 0,65
AE-25/4 SC_ no AEP-25/4 SC_ no
12, carbon/
SiC Viton 123 X 2,5 NBR
0,08 and
0,2
G 1 AE-26/4 SC_ no AEP-26/4 SC_ no
12, carbon/
SiC Viton 123 X 2,5 NBR
0,08 and
0,2
AE-25/2 SC_ no AEP-25/2 SC_ no
12, carbon/
SiC Viton 123 X 2,5 NBR 0,65
AE-26/2 SC_ no AEP-26/2 SC_ no
12, carbon/
SiC Viton 123 X 2,5 NBR 0,65
G 1 1/4 AE-32/4 SC_ no AEP-32/4 SC_ no
12, carbon/
SiC Viton 145 X 2,5 NBR 0,2-0,37
AE-33/4 SC_ no AEP-33/4 SC_ no
12, carbon/
SiC Viton 145 X 2,5 NBR 0,2-0,37
DN 32 L-32/4 SC_ no no no
12, carbon/
SiC EPDM 100 X 2,5 NBR
0,08 and
0,2
L-32/2 SC_ no no no
12, carbon/
SiC EPDM 100 X 2,5 NBR 0,65
DN 40 L-40A/4 SC_ no no no
12, carbon/
SiC EPDM 145 X 2,5 NBR 0,2-0,37
DN 50 L-50A/4 SC_ no LP-50A/4 SC_ no
12, carbon/
SiC EPDM 150 X 3 NBR
0,2 and
0,55
DN 65 L-65A/4 SC_ LH-65A/4 SC_ no no
18, carbon/
SiC EPDM 179,3 X 5,7 EPDM
0,55 and
0,75
DN 80 L-80A/4 SC_ LH-80A/4 SC_ no no
18, carbon/
SiC EPDM 179,3 X 5,7 EPDM
0,55 and
0,75
DN 100 AL-1102/4 SC_ ALH-1102/4 SC_ ALP-1102/4 SC_ ALS-1102/4 SC_
18, carbon/
SiC EPDM 179,3 X 5,7 EPDM 0,75

PUMP SERVICE
9
245
04/2013 Subject to change without prior notice. www.kolmeks.com
No. NAME
1 Electric motor
2 pump housing
3 Impeller
5 Sealing flange
8 Base plate
16 Cover (AT- and T-
series)
24 Nut / Screw
25 Washer
26 Key
Spare parts
No. NAME
40 Mechanical seal
50 O-ring / Gasket
55 Gasget (AT- and T-series)
56/57 Wear ring (N-series)
60 Nut / Screw
65 Screw (AT- and T-series)
67 Screw
80 Pipe joint (AMK-25,-26,
AHV-25, AE-26,-33, AP-33)
80/81 Pipe joint (ALH-series)
86 Pipe (ALH-series)
93 Flap device (AT- and T-series)
94 Pin (AT- and T-series)

PUMP SERVICE
9
246 04/2013 Subject to change without prior notice.
www.kolmeks..com
Replacing motor unit for pumps less than 1.5 kW
Note! Only an authorized person may carry out the replacement.
2) Detach the motor cable.
Open the screws/bolts of the
operating unit.
Starting situation. The pump
is running normally.
1) Stop the pump, open
any possible safety switch
and remove fuses. En-
sure that no one is able
to switch the current on,
even by accident, during
the replacement. Close the
valves.
3) Lift the operation unit
from the pump housing.
Watch out for hot water!
6) Connect the motor cable
and open the valves. Start
the pump and check the di-
rection of rotation. Vent the
system. Monitor the opera-
tion of the pump.
5) Install a new motor
unit. Tighten the screws/
bolts of the unit evenly.
4) Replace the gasket/O-ring
of the housing.

PUMP SERVICE
9
247
04/2013 Subject to change without prior notice. www.kolmeks.com
Replacing motor unit for pumps over 1.5 kW
Note! Only an authorized person may carry out the replacement.
Starting situation: The pump
is running normally.
1) Stop the pump, open a
possible safety switch and
remove fuses. Ensure that
no one is able to switch the
current on, even by accident,
during the replacement.
Close the valves.
2) Close the valves and de-
tach the connecting cable of
the motor. Next, detach the
flush pipe (in ALH pumps).
Open the screws/bolts of the
operation unit.
3) Lift the operation unit by
means of a hoist. Watch out
for hot water!
4) Replace the gasket/O-ring
of the housing.
5) Install a new motor unit.
Tighten the screws/bolts of
the unit evenly.
6) Connect the motor cable
and open the valves. Start
the pump and check the di-
rection of rotation. Vent the
system. Monitor the opera-
tion of the pump.

PUMP SERVICE
9
248 04/2013 Subject to change without prior notice.
www.kolmeks..com
Replacing impeller
2) Install the motor unit
in a vertical position.
1) Detach the motor unit
as usual (see Replacing
motor and replacement
motor unit).
3) Open the screw/bolt of
the impeller.
4) Use screwdrivers to
detach the impeller.
5) Use an extractor if
necessary.
6) The motor unit is
without an impeller.
Replace the shaft seal
when necessary (see
Replacing a shaft seal).
8) Attach the motor unit
as usual.
7) Install a new impeller.
If required, you can lightly
tap the impeller with a
rubber mallet until flush
with the ridge. Tighten
the screw/bolt of the
impeller.

PUMP SERVICE
9
249
04/2013 Subject to change without prior notice. www.kolmeks.com
Replacing shaft seal
Stop the pump and close the shut-o valves. Detach the motor unit from the pump housing. (see replacing motor unit).
Detach the impeller of the pump (see Replacing an impeller).
Starting situation. The
motor unit with the
impeller detached.
1) Detach the shaft seal
using two screwdrivers.
Do not damage the seal-
ing surface of the shaft.
2) Also detach the
sealing flange from
the motor front plate
using two screwdrivers.
If needed, replace the
sealing flange with a
new one.
3) The motor unit disas-
sembled, with installa-
tion tools.
Detaching seal
Installing mechanical seal
Check the housing and O-ring groove for the stationary ring in the sealing flange are clean. Check the O-ring and lubricate it
with soap water, not with oil. Then install the O-ring in the groove of the sealing flange (in the stationary ring for BO- and
BP-marked seals).
Lubricating and installing O-ring
NOTE! Touch the seal parts with clean hands only, and as little as possible and with extreme care.

PUMP SERVICE
9
250 04/2013 Subject to change without prior notice.
www.kolmeks..com
Check that the stationary ring is undamaged, clean, smooth and not scratched. If the stationary ring is packed in protective
foil, detach it with a knife, carefully minding the rotating surface. Then, remove the grease with a dry and clean cloth. Press
the stationary ring into the sealing flange with the smoother surface facing you (the pump). Ensure that the O-ring does not
push the ring out. If this happens, use more lubrication. Finally, clean the rotating surface of the stationary ring with a clean
and lint-free cloth or towel which is dampened with a suitable organic solvent, e.g. methyl alcohol or spirit. Alternatively,
the stationary ring can be installed with a clean lint-free cloth without fingers touching the rotating surface. Finally, the
rotating surface should be blown clean with compressed air.
Pressing stationary ring into the sealing flange
Installing sealing flange onto D-end motor flange
Install the sealing flange onto the motor. Place the assembly sleeve of the installation tool so that it forms a shaft
extension. In large pumps, first install the sealing flange onto the motor and then the stationary ring (BO- and BP-marked
seals).

PUMP SERVICE
9
251
04/2013 Subject to change without prior notice. www.kolmeks.com
Assembly sleeve as shaft extension
Soaping assembly sleeve
Check that the seal body, bellows and rotating ring are clean and undamaged. If the rotating surface of the rotating ring is
dirty, clean it with a clean and lint-free cloth which is dampened with a suitable organic solvent, e.g. methyl alcohol or spirit.
Lubricate the shaft and the seal elastomer bellows suitably with soapy water, not with oil.

PUMP SERVICE
9
252 04/2013 Subject to change without prior notice.
www.kolmeks..com
Pushing bellows onto shaft
Detach the spring (if separate) and, using even pressure, push the bellows onto the shaft using the installation mandrel
until the rotating surfaces meet. Do not press too hard. If the spring is attached to the frame, install the whole seal onto
the shaft from its bellows part (end of seal) by pushing with a suitable sleeve. If the rotating ring of the seal does not stay
fast in the seal, install it first and ensure that when installing the seal frame, the frame and the rotating ring are in place
correctly.
Note! Do not touch the rotating surface of the rotating ring.
Installing spring, back plate and impeller
Rotate the shaft sligtly and carefully and ensure that the seal fits well. Then, install spring, back plate (if separate) and
impeller.