Munsch NPC Series User manual

Standard Chemical Pump
Operating manual NPC series
Version BA-2005.07
Print-Nr. 02
VM-Nr. EN
Munsch Chemie-Pumpen GmbH
Im Staudchen
56235 Ransbach-Baumbach
Germany
Phone: [phone]
Fax: [phone]
E-mail: mun[email protected]
Internet: http://www.munsch.de
Technical alterations reserved.

Table of contents
Table of contents
1 About this document ............................... 6
1.1 Target groups ................................. 6
1.2 Other applicable documents . . . . . . . .. . . . . . . . 6
1.3 Warning labels and symbols ................ 7
1.4 Technical terms ............................... 7
2 Security .............................................. 8
2.1 Intended use .................................. 8
2.2 General safety instructions .................. 8
2.2.1 Product safety ................................ 8
2.2.2 Duties of the operating company . . . . . . . . . .. 9
2.2.3 Duties of the operating personnel . . . . . . . .. . . 9
2.3 Special hazards .............................. 9
2.3.1 Explosion hazard area ....................... 9
2.3.2 Hazardous pumped media . . . . . . .. . . . . . . .. . . 9
3 Layout and function ................................ 10
3.1 Labels ......................................... 10
3.1.1 Type plate ..................................... 10
3.1.2 ATEX plate .................................... 10
3.1.3 Pump type code . . . . . . . . . . .. . . . . . . .. . . . . . . .. . . 10
3.2 Layout ......................................... 11
3.3 Shaft seals .................................... 11
3.3.1 Mechanical seals ............................. 11
3.4 Auxiliary operating systems ................. 12
3.4.1 Sealing systems .............................. 12
4 Transport, storage and disposal .................. 13
4.1 Transport ...................................... 13
4.1.1 Unpacking and inspection on delivery .. .. . . 13
4.1.2 Lifting .......................................... 13
4.2 Preservation .................................. 14
4.3 Storage ....................................... 14
4.4 Disposal ....................................... 14
5 Setup and connection .............................. 15
5.1 Preparing the setup .......................... 15
5.1.1 Checking the ambient conditions . . . . . . . .. . . 15
5.1.2 Preparing the setup site ..................... 15
5.1.3 Preparing the foundation and setup
surface ........................................ 15
5.1.4 Installing the heat insulation . . . . .. . . . . . .. . . . . 15
5.2 Setup with foundation ........................ 16
5.2.1 Setting the pump aggregate on the
foundation .................................... 16
5.2.2 Fastening the pump aggregate . . . . . . .. . . . . . 16
5.3 Setup without foundation .................... 17
5.4 Mounting the motor .......................... 17
5.5 Planning the piping ........................... 17
5.5.1 Avoid contamination of the piping . . . . . . . . . . . 17
5.5.2 Specifying supports and flange
connections . . . .. . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . 17
5.5.3 Specifying nominal widths ................... 18
5.5.4 Specifying pipe lengths ...................... 18
5.5.5 Optimizing cross-section and direction
changes ....................................... 18
5.5.6 Arranging for safety and control devices
(recommended) .............................. 18
5.6 Connecting the pipes ........................ 18
5.6.1 Installing auxiliary pipes ..................... 18
5.6.2 Installing the suction pipe . . . . . . . . .. . . . . . . .. . . 18
5.6.3 Installing the pressure pipe . . . . . . . . . . . .. . . . . . 18
5.6.4 Inspection for stress-free pipe
connections . . . .. . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . 19
5.6.5 Inspecting the support foot for
distortion ...................................... 19
5.7 Electrical connection ......................... 19
5.7.1 Connecting the motor ........................ 19
5.7.2 Checking the direction of rotation . . . . . . . .. . . 19
5.8 Fine alignment of the coupling . . . . . .. . . . . . . . 20
5.9 Aligning the motor ............................ 20
5.9.1 Aligning the motor using sets of shims .. . . . 20
6Operation ............................................ 21
6.1 Preparations for the initial start-up . . . . . . . . .. 21
6.1.1 Identifying the pump type .................... 21
6.1.2 Lubricating the bearings ..................... 21
6.1.3 Preparing auxiliary operating systems (if
available) ..................................... 21
6.1.4 Filling and bleeding .......................... 21
6.2 Start up ....................................... 22
6.2.1 Switching on .................................. 22
6.2.2 Switching off .................................. 22
6.3 Shut-down .................................... 23
6.4 Start-up following a shutdown period . . .. . .. 23
6.5 Running the stand-by pump ................. 23
7 Maintenance ......................................... 24
7.1 Inspections . . . . . . .. . . . . . . .. . . . . . . .. . . . . . .. . . . . 24
7.2 Maintenance .................................. 24
7.2.1 Roller bearings with grease lubrication .. . . . 24
7.2.2 Roller bearings with oil lubrication . . . . . . . . . . 25
7.2.3 Stationary seal rings ......................... 25
7.3 Disassembling . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . 25
7.3.1 Returning the pump to the manufac-
turer ........................................... 26
7.3.2 Preparations for disassembling . . . . . . . . . . . . . 26
7.3.3 Loosening connectors (if available) . . .. . . . . . 27
7.3.4 Extracting the volute casing . . . . . . . .. . . . . . . .. 27
7.3.5 Disassembling the impeller . . . . . . . . . .. . . . . . . . 27
7.3.6 Disassembling a casing cover with
MUNSCH-REA-C mechanical seal . . . . . . . .. 28
7.3.7 Disassembling the atmosphere-side
stationary seal ring ........................... 28
7.3.8 Disassembling the bearing bracket . . . . . . . .. 29
7.3.9 Disassembling the pump shaft . . . . . . . .. . . . . . 29
7.4 Assembling ................................... 30
2 NPC series BA-2005.07 EN – 02

Table of contents
7.4.1 Preparations for assembling .. . . . . . . .. . . . . . . 30
7.4.2 Fitting the pump shaft ........................ 30
7.4.3 Fitting the bearing bracket . .. . . . . . . .. . . . . . . .. 30
7.4.4 Fitting the casing cover . . . . . . . . . . . .. . . . . . . .. . 30
7.4.5 Fitting the pump into the installation . . . . . ... 30
7.5 Ordering replacement parts ................. 30
8 Disturbance recovery .............................. 31
9 Appendix ............................................. 34
9.1 Sectional drawings ........................... 34
9.1.1 Part numbers and designations ............. 34
9.1.2 Overview sectional drawing . . . . . . . . . . .. . . . . . 36
9.1.3 Variants ....................................... 36
9.2 Technical specifications ...................... 40
9.2.1 Ambient conditions ........................... 40
9.2.2 Parameters for auxiliary operating
systems ....................................... 40
9.2.3 Noise pressure level . . . . .. . . . . . . .. . . . . . . .. . . . 40
9.2.4 Tightening torques ........................... 41
9.2.5 Lubricants . . . . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . 42
9.2.6 Detergents .................................... 42
9.2.7 Socket loads according to ISO 5199 . . . . . . . 42
9.3 Replacement parts for 2 years of continuous
operation according to DIN 24296 . . . . . . . . . . 43
EN – 02 BA-2005.07 NPC series 3

Table of contents
List of figures
Fig. 1 Type plate (example) ........................ 10
Fig. 2 ATEX plate (example) ........................ 10
Fig. 3 Pump type code (example) . . . . . . . . . . . . .. . . . . 10
Fig. 4 Layout NPC ................................... 11
Fig. 5 Double mechanical seal with quench
(operating principle) .......................... 12
Fig. 6 Double mechanical seal with foreign blocking
(operating principle) .......................... 12
Fig. 7 Fastening the lifting gear to the pump
aggregate ..................................... 13
Fig. 8 Fastening the lifting gear to the pump . . . . . . 13
Fig. 11 Setup without foundation .................... 17
Fig. 12 Straight pipe lengths upstream and down-
stream of the pump (recommended) . . . . . . . 18
Fig. 16 Oil level in sight glass ........................ 21
Fig. 17 Loosening the flushing connector or supply
connectors REA-C/D . . . . . . . . . . . . .. . . . . . .. . . . . 27
Fig. 18 Extracting the volute casing . . . . . . . . . . .. . . . . . 27
Fig. 19 Disassembling the impeller . .. . . . . . . .. . . . . . . . 27
Fig. 20 Disassembling a casing cover with
MUNSCH-REA-C mechanical seal . . . . . . . .. 28
Fig. 21 Disassembling MUNSCH-REA-D stationary
seal ring ....................................... 28
Fig. 22 Disassembling the bearing bracket (grease
lubrication, L16A, L18B, L20A) . . . . . .. . . . . . . . 29
Fig. 23 Disassembling the pump shaft (no lifetime
lubrication) .................................... 29
Fig. 24 Disassembling the pump shaft (with lifetime
lubrication) .................................... 29
Fig. 25 Fitting the casing cover ...................... 30
Fig. 26 NPC – overview sectional drawing . . . . . . . . . 36
Fig. 27 NPC – casing foot ............................ 36
Fig. 28 Emptying (optional) .......................... 36
Fig. 29 MUNSCH-REA-C single mechanical
seal ............................................ 37
Fig. 30 MUNSCH-REA-C/D double mechanical
seal ............................................ 37
Fig. 31 Stationary seal ring holder (only for double
mechanical seal) ............................. 37
Fig. 32 Shutdown/continuous flushing (flushing of
pump interior) ................................. 37
Fig. 33 Single mechanical seal with spring chamber
flushing (supply connectors) . . . . . . . .. . . . . . . . 37
Fig. 34 MUNSCH-REA-C/D supply connec-
tors ............................................ 38
Fig. 35 Casing cover (split) .......................... 38
Fig. 36 Bearing bracket L16A (grease-lubricated
bearing) ....................................... 38
Fig. 37 Bearing bracket L16A (grease-lubricated
bearing, lifetime lubrication) ................. 38
Fig. 38 Bearing bracket L16A (oil-lubricated
bearing) ....................................... 39
Fig. 39 Bearing bracket L18B (grease-lubricated
bearing) ....................................... 39
Fig. 40 Bearing bracket L18B (oil-lubricated
bearing) ....................................... 39
Fig. 41 Blocking – pressure of sealing medium . . . .. 40
Fig. 42 Socket loads at the pump . . . . . . . .. . . . . . . .. . . 42
4 NPC series BA-2005.07 EN – 02

Table of contents
List of tables
Tab. 1 Target groups and their duties . . . . . . . . . . . .. . 6
Tab. 2 Other applicable documents and their
purpose ....................................... 6
Tab. 3 Warning labels and consequences of
disregarding them ............................ 7
Tab. 4 Symbols and their meaning ................. 7
Tab. 5 Technical terms and their meaning . . . . . . . .. 7
Tab. 6 Quenching – variants and characteris-
tics ............................................. 12
Tab. 7 Foreign blocking – variants and
characteristics ................................ 12
Tab. 8 Action to be taken for pump shutdowns .... . 23
Tab. 9 Measures depending on pumped medium
behavior ....................................... 23
Tab. 10 Actions to be taken after prolonged shutdown
periods ........................................ 23
Tab. 11 Actions for return ............................. 26
Tab. 12 Fault/number assignment . . . . . . . . . .. . . . . . . .. 31
Tab. 13 Troubleshooting list .......................... 33
Tab. 14 Designations of components listed with part
numbers ...................................... 35
Tab. 15 Ambient conditions ........................... 40
Tab. 16 Operating parameters for sealing medium in
open flow system ............................. 40
Tab. 17 Noise pressure level . . . . . . . . . . .. . . . . . . .. . . . . . 40
Tab. 18 Steel/cast pairing . . . . . .. . . . . . . .. . . . . . . .. . . . . . . 41
Tab. 19 Socket head cap screw 914.1 - steel/steel
pairing ......................................... 41
Tab. 20 Lubricating greases .......................... 42
Tab. 21 Minimum amounts for grease lubrica-
tion ............................................ 42
Tab. 22 Lubricating oils ............................... 42
Tab. 23 Minimum amounts for oil lubrication . . . . . . . . 42
Tab. 24 Detergents .................................... 42
Tab. 25 Socket loads – forces . . . . . . . . . .. . . . . . . .. . . . . . 42
Tab. 26 Socket loads – torques . . . . . . . .. . . . . . . .. . . . . . 42
Tab. 27 Replacement parts for 2 years' continuous
operation ...................................... 43
EN – 02 BA-2005.07 NPC series 5

About this document
1 About this document
This manual
• is part of the pump
• applies to the pump series mentioned above
• describes safe and appropriate operation during all oper-
ating phases
1.1 Target groups
Target group Duty
Operating company Keep this manual available at the site of operation of the
installation, including for later use.
Ensure that personnel read and follow the instructions in this
manual and the other applicable documents, especially all safety
information and warnings.
Observe any additional rules and regulation referring to the
installation.
Qualified personnel, fitter Read, observe and follow this manual and the other applicable
documents, especially all safety information and warnings.
Tab. 1 Target groups and their duties
1.2 Other applicable documents
Document Purpose
ATEX additional instructions Operation in explosion hazard areas
Order data sheet Technical specifications, conditions of operation
Setup drawing Setup dimensions, connection dimensions, etc.
Technical description Technical specifications, operating limits
Sectional drawing Sectional drawing, parts numbers, component designations
Supplier documentation Technical documentation for parts supplied by subcontractors
Replacement parts list Ordering replacement parts
Safety certificate Returning the pump to the manufacturer
Tab. 2 Other applicable documents and their purpose
6 NPC series BA-2005.07 EN – 02

About this document
1.3 Warning labels and symbols
Warning label Risk level Consequences of disregard
DANGER Immediate acute risk Death, grievous bodily harm
WARNING Potential acute risk Death, grievous bodily harm
CAUTION Potential hazardous situation Minor bodily harm
CAUTION Potential hazardous situation Material damage
Tab. 3 Warning labels and consequences of disregarding them
Symbol Meaning
Safety warning sign
Take note of all information highlighted by the safety warning sign
and follow the respective instructions to avoid injury or death.
Safety instruction
1. , 2. , ... Step-by-step safety instructions
Precondition
→Cross reference
Information, hint
Tab. 4 Symbols and their meaning
1.4 Technical terms
Term Meaning
Sealing medium Medium for locking or quenching of shaft seals
Auxiliary operating systems Systems for operating the pump
Tab. 5 Technical terms and their meaning
EN – 02 BA-2005.07 NPC series 7

Security
2 Security
The manufacturer does not accept any liability for events
resulting from disregard of the entire documentation.
2.1 Intended use
• Only use the pump for pumping the agreed pumped media
(→ Order data sheet).
• Adhere to operating limits and size-dependent minimum
flow rate.
• Avoid dry running:
Initial damage such as destruction of mechanical seal and
plastic parts within only a few seconds.
– Make certain that the pump is never put into operation
and never operated without a pumped medium.
• To avoid cavitation:
– Fully open the suction-side armature and do not use
for adjusting the flow rate.
– Do not open the pressure-side armature beyond the
agreed operating point.
• To avoid overheating:
– Do not operate the pump while the pressure-side arma-
ture is closed.
– Observe the minimum flow rate (→ Order data sheet).
• To avoid damage to the motor:
– Do not open the pressure-side armature beyond the
agreed operating point.
– Observe the allowed number of motor switch-ons per
hour (→ Manufacturer's specifications).
• Consult with the manufacturer about any other use of the
pump.
Prevention of self-evident misuse (examples)
• Observe the operating limits of the pump regarding operat-
ing temperature, pressure, flow rate and speed (→ Order
data sheet).
• The power uptake of the pump will increase with increasing
density of the pumped medium. To avoid any overload for
the pump, the coupling and the motor, do not exceed the
allowable density (→ Order data sheet).
A lower density is allowed. Adapt auxiliary systems accord-
ingly.
• Adhere to limits on solids content and grit size when pump-
ing solids-carrying fluids (→ Order data sheet, technical
description).
• When using auxiliary operating systems, ensure that
there is a continuous supply of the appropriate operating
medium.
2.2 General safety instructions
Take note of the following instructions before carrying out
any work.
2.2.1 Product safety
The pump has been constructed according to up-to-date tech-
nology and established technical safety rules. Nevertheless,
operation of the pump can involve risks to life and health of the
user or of third parties, or risks of damaging the pump and other
property.
• Operate the pump only if it is in perfect technical condition,
according to its intended use, in awareness of safety and
risks and in adherence to the instructions in this manual.
• Keep this manual and all other applicable documents com-
plete, legible and accessible to personnel at all times.
• Refrain from any procedures and actions that would
expose personnel or third parties to any risk.
• Should there be any safety-relevant fault, deactivate the
pump immediately and have the fault corrected by appro-
priate personnel.
• In addition to the entire documentation for the product,
always comply with statutory or other safety and acci-
dent-prevention rules and with the applicable standards
and guidelines in the country where the pump is operated.
8 NPC series BA-2005.07 EN – 02

Security
2.2.2 Duties of the operating company
Safety-conscious operating
• Operate the pump only if it is in perfect technical condition,
according to its intended use, in awareness of safety and
risks and in adherence to the instructions in this manual.
• Ensure that the following safety aspects are observed and
monitored:
– adherence to intended use
– statutory or other safety and accident-prevention rules
– safety regulations governing the handling of hazardous
substances
– applicable standards and guidelines in the country
where the pump is operated
• Make protective equipment available.
Qualified personnel
• Make certain that all personnel tasked with work on the
pump have read and understood this manual and all other
applicable documents, especially the safety, maintenance
and repair instructions, before they begin the job.
• Organize responsibilities, who is in charge of any specific
duty and how personnel is supervised.
• Ensure that all work is carried out by specialist technicians
only:
– fitting, repair and maintenance work
– work on the pump electrical system
• Make certain that trainee personnel is supervised by a spe-
cialist technician when performing tasks on the pump.
Safety installations
• Provide the following safety installations and verify their
integrity:
– for hot and moving parts: device-side contact protec-
tion on the pump
– in case of potential electrostatic charging: appropriate
grounding
Warranty
• Obtain the manufacturer's approval prior to carrying out
any modification, repair or alterations during the warranty
period.
• Only use original parts or parts that have been approved
by the manufacturer.
2.2.3 Duties of the operating personnel
• Observe and keep legible all directions given on the pump,
e.g. the arrow indicating the direction of rotation and the
markings for fluid connections.
• Do not remove the contact protection for hot, cold and mov-
ing parts during operation.
• Use protective equipment if necessary.
• Carry out work on the pump only while the pump is not
running.
• Isolate the motor from its supply voltage and keep it locked
in that state while carrying out any fitting or maintenance
work.
• Mount the safety installations on the pump according to
instructions after completion of work on the pump.
2.3 Special hazards
2.3.1 Explosion hazard area
• (→ ATEX additional instructions).
2.3.2 Hazardous pumped media
• Observe the safety regulations for the handling of haz-
ardous substances when working with hazardous pumped
media (e.g. hot, flammable, poisonous or potentially harm-
ful).
• Use protective equipment when carrying out any work on
the pump.
EN – 02 BA-2005.07 NPC series 9

Layout and function
3 Layout and function
3.1 Labels
3.1.1 Type plate
MUNSCH Chemie-Pumpen GmbH
D-56235 Ransbach-Baumbach
n
W.-Nr.
Lfrd.
impeller
serial-no.
P
Q
type
Typ
-1
Nm
M
kg/dm
Baujahr
H
kW
m /h
3
year
m
3
min
9
8
7
3
4
5
6
1
2
10
Fig. 1 Type plate (example)
1Pumptype
2 Serial number
3 Construction year
4 Total differential head
5 Density
6Torque
7 Speed
8 Power consumption
9Flowrate
10 Impeller diameter
3.1.2 ATEX plate
1
2
Fig. 2 ATEX plate (example)
1 Explosion protection mark
2 Reference to ATEX additional instructions
3.1.3 Pump type code
1
2
3
4
NPC 50 - -32 200
Fig. 3 Pump type code (example)
1 Pump series
2 Suction flange DN [mm]
3 Pressure flange DN [mm]
4 Impeller nominal diameter [mm]
10 NPC series BA-2005.07 EN – 02

Layout and function
3.2 Layout
2 3 4
56
1
Fig. 4 Layout NPC
1 Impeller
2 Casing armour plating
3 Volute casing
4 Bearing bracket
5 Pump shaft
6 Casing cover
3.3 Shaft seals
Only one of the following shaft seals can be used.
3.3.1 Mechanical seals
Mechanical seals will always show some functional drip
leakage.
• Single mechanical seal
• Double mechanical seal with quench
• Double mechanical seal with foreign blocking
EN – 02 BA-2005.07 NPC series 11

Layout and function
3.4 Auxiliary operating systems
3.4.1 Sealing systems
Only one of the following sealing systems can be used.
Quenching
1 2
3
Fig. 5 Double mechanical seal with quench
(operating principle)
1 Pumped medium
2 Sealing medium (unpressurized)
3 Double mechanical seal
With quenching, the pressure of the pumped medium exceeds
the pressure of the sealing medium. The sealing friction sur-
faces of the product-side seal are lubricated by the pumped
medium.
Application examples:
• pumped media that crystallize in air, causing long-term
damage to the seal
• prevention of odors
• seal cooling
Variant Sealing medium
characteristics
Open system • supplied and drained
continuously
• unpressurized
Closed system • circulates in a closed
cycle
• unpressurized
Tab. 6 Quenching – variants and characteristics
Blocking
1 2
3
Fig. 6 Double mechanical seal with foreign blocking
(operating principle)
1 Pumped medium
2 Sealing medium (pressurized)
3 Double mechanical seal
With foreign blocking, the pressure of the sealing medium
exceeds the pressure of the pumped medium. The sealing
friction surfaces are lubricated by the sealing medium.
Application examples:
• pumped media that crystallize or carry solids, causing long-
term damage to the seal
• toxic pumped media
• pumped media presenting an environmental hazard
Variant Sealing medium
characteristics
Open flow system • supplied and drained
continuously
• pressurized
Closed flow system • circulates in a closed
cycle
• pressurized
Tab. 7 Foreign blocking – variants and characteristics
12 NPC series BA-2005.07 EN – 02

Transport, storage and disposal
4 Transport, storage and disposal
4.1 Transport
Weight specifications (→ Individual order documentation).
4.1.1 Unpacking and inspection on delivery
1. Unpack the pump/aggregate on delivery and inspect for
transport damage.
2. Report any transport damage to the manufacturer without
delay.
3. Dispose of packaging material according to local regula-
tions.
4.1.2 Lifting
DANGER
Death or crushing of limbs caused by falling loads!
Use lifting gear appropriate for the total weight to be trans-
ported.
Fasten the lifting gear as shown in the illustrations below.
Do not stand under suspended loads.
Fig. 7 Fastening the lifting gear to the pump aggregate
Fig. 8 Fastening the lifting gear to the pump
Lift the pump/aggregate appropriately.
EN – 02 BA-2005.07 NPC series 13

Transport, storage and disposal
4.2 Preservation
No preservation required.
Do not preserve the pump.
4.3 Storage
CAUTION
Material damage due to inappropriate storage!
Store the pump appropriately.
1. Seal all openings with blind flanges, blind plugs or plastic
covers.
2. For models with oil-lubricated bearings and downtimes in
excess of one year:
– Dismount any existing reservoir
– Dismount any existing oil level controller
– Seal the tap hole
– Fill the bearing bracket with oil, up to the brim
– Seal the bleeding hole
3. Make certain that the storage room meets the following
conditions:
–dry
– frost-free
– vibration-free
4. Turn shaft once a month.
5. Make certain that the shaft and the bearing change their
rotational position in the process.
4.4 Disposal
Plastic parts can be contaminated by poisonous or radio-
activepumpedmediatosuchanextentthatcleaningwill
be insufficient.
WARNING
Risk of poisoning and environmental damage caused by
pumped medium or oil!
Use protective equipment when carrying out any work on
the pump.
Prior to disposal of the pump:
– Collect pumped medium and oil or grease running out
and dispose of the pumped medium according to local
regulations.
– Neutralize residues of pumped medium in the pump.
Dismount plastic parts and dispose of the parts according
to local regulations.
Dispose of pump according to local regulations.
14 NPC series BA-2005.07 EN – 02

Setup and connection
5 Setup and connection
For pumps in explosion hazard areas (→ ATEX additional
instructions).
CAUTION
Material damage caused by dirt!
Do not remove transport locks until immediately before set-
ting up the pump.
Do not remove covers and transport and sealing covers
until immediately before connecting the piping to the pump.
5.1 Preparing the setup
5.1.1 Checking the ambient conditions
1. Make certain that the required ambient conditions are ful-
filled (→ 9.2.1 Ambient conditions, Page 40).
2. For setup sites > 1000 m above sea level, consult with the
manufacturer.
5.1.2 Preparing the setup site
Make certain that the setup site meets the following condi-
tions:
– pump is freely accessible from all sides
– sufficient space for installation/removal of the pipes
and for maintenance and repair work, especially for the
removal and installation of the pump and the motor
– pump not exposed to external vibrations (damage to
bearings)
– frost protection
5.1.3 Preparing the foundation and setup surface
Setup options:
– with concrete foundation
– with steel foundation frame
– without foundation
Make certain that the foundation and setup surface meet
the following conditions:
– level surface
– clean (no oil, dust or other impurities)
– foundation and surface can support the weight of the
pump aggregate and all operating forces
– safe stand of the pump aggregate ensured
– for concrete foundation: Standard concrete of strength
class B 25
5.1.4 Installing the heat insulation
Only necessary to maintain the temperature of the pumped
medium.
CAUTION
Material damage caused by overheating!
Only install the heat insulation on the volute casing.
Install the heat insulation appropriately.
EN – 02 BA-2005.07 NPC series 15

Setup and connection
5.2 Setup with foundation
CAUTION
Material damage due to base plate distortion!
Set and fasten the base plate on the foundation as
described in the following.
5.2.1 Setting the pump aggregate on the foundation
✔Implements, tools and materials:
– foundation bolts (→ Setup drawing)
– steel washers
– mortar grout, non-shrinking
– spirit level
1. Lift the pump aggregate (→ 4.1 Transport, Page 13).
2. Working from below, hang the foundation bolts in the fixa-
tion holes of the base plate.
Observe the manufacturer's instruction when using chem-
ical anchors.
3. Set down the pump aggregate on the foundation. When
doing this, sink the foundation bolts into the prepared
anchoring holes.
32 1 2
Fig. 9 Setup with foundation
4. Use steel washers to align the pump aggregate to height
and system measures as described in the following:
– Position 1 steel washer (2) each left and right of each
foundation bolt (1).
– If the distance between anchoring holes is > 750 mm,
position additional steel washer (3) centrally at each
side of the base plate.
5. Make certain that the base plate and the steel washers are
in full surface contact.
6. Use machine spirit level to check that the allowable height
deviation (1 mm/m) lengthwise and crosswise is not
exceeded.
7. Repeat procedure until the base plate is correctly aligned.
5.2.2 Fastening the pump aggregate
Filling out the base plate with mortar grout will improve the
damping behavior.
1. Fill the anchoring holes with mortar grout.
2. Once the mortar grout has set, screw on the base
plate at three points with the specified tightening torque
(→ 9.2.4 Tightening torques, Page 41).
3. Before tightening the remaining bolts, compensate any
unevenness of the fixation surface, using metal shims next
to each bolt.
4. To inspect the pump aggregate for distortions, using a hair
ruler:
1
Fig. 10 Checking for distortions
– Measure in two planes at an angle of 90° to each other
on the circumference of the coupling.
– Measure the light gap at the outer diameter with hair
ruler (1):
Position the hair ruler across both halves of the cou-
pling.
If there are major deviations, loosen the fixation at the
base plate and correct the distortion by inserting more
shims.
– Fill the base plate with molding material if applicable.
Knock on the base plate to ensure that no cavities are
created in the process.
Couplings with a spacer piece (Dismountable coupling) can
also be inspected with a dial gauge.
16 NPC series BA-2005.07 EN – 02

Setup and connection
5.3 Setup without foundation
✔Implements, tools and materials:
–Wrench
– Spirit level
1
1
1
1
2
3
4
Fig. 11 Setup without foundation
1. Lift the pump aggregate (→ 4.1.2 Lifting, Page 13).
2. Mount the four leveling feet (1) as shown in the figure.
3. Set down the pump aggregate on the setup surface.
4. Adjust the height of the base plate using leveling feet (1)
as shown above:
– Use wrench to hold the hexagon at leveling foot (4).
– Slacken hexagon nut (2).
– Adjust height by turning hexagon nut (3).
– Tighten hexagon nut (2) (→ 9.2.4 Tightening torques,
Page 41).
– Use machine spirit level to check that the allowable
height deviation (1 mm/m) lengthwise and crosswise
is not exceeded.
– Repeat procedure until the base plate is aligned cor-
rectly.
5.4 Mounting the motor
Only necessary if the pump aggregate is assembled at he
setup site.
CAUTION
Material damage caused by knocks and blows!
Do not cant the coupling halves when pushing on the motor.
Do not knock or hit any component of the pump.
1. Apply a very thin film of molybdenum sulfite (e.g. Molykote)
on the pump and motor shaft ends.
2. Insert keys.
3. Without a mounting device: Remove rubber buffers and
heat coupling halves to approx. 100 °C.
4. Slide on the pump-side and motor-side coupling halves
until the shaft end and the coupling center are flush with
each other. Keep to the specified distance between the
coupling halves (→ Assembly instructions for the coupling).
5. Tighten the threaded pins at both coupling halves.
6. Use suitable metal shims at the motor to adjust the motor
shaft end to the height of the pump shaft end.
7. Turn in the motor screws, but do not tighten them yet
(→ 5.9 Aligning the motor, Page 20).
5.5 Planning the piping
5.5.1 Avoid contamination of the piping
CAUTION
Material damage due to impurities in the pump!
Make certain that no impurities can get into the pump.
1. Clean all piping components and armatures prior to assem-
bly.
2. Ensure that no flange gaskets are protruding inwards.
3. Remove blind flanges, plugs, protective foils and/or protec-
tive paints on flanges.
5.5.2 Specifying supports and flange connections
CAUTION
Material damage due to excessive forces and torque from
piping on the pump!
Do not exceed allowable limits (→ 9.2.7 Socket loads
according to ISO 5199, Page 42).
1. Calculate pipe forces and take into account every possible
operating condition:
– cold/warm
– empty/full
– unpressurized/pressurized
– position shifts of flanges
2. Ensure that pipe supports have permanent low-friction
properties and will not seize up through corrosion.
EN – 02 BA-2005.07 NPC series 17

Setup and connection
5.5.3 Specifying nominal widths
Keep flow resistance in pipes as low as possible.
1. Specify suction pipe nominal width ≥ suction flange nominal
width.
2. Specify pressure pipe nominal width ≥ pressure flange
nominal width.
5.5.4 Specifying pipe lengths
C
D
B
A
Fig. 12 Straight pipe lengths upstream and downstream
of the pump (recommended)
A>5xDNs
B DNs
C DNd
D>5xDNd
Observe recommended minimum parameters when install-
ing the pump.
Suction side: Shorter pipes are allowable but can restrict
hydraulic performance data.
Pressure side: Shorter pipes are allowable but can lead to
increased operating noise.
5.5.5 Optimizing cross-section and direction changes
1. Avoid radii of curvature smaller than 1.5 times the nominal
pipe width.
2. Avoid abrupt changes of cross-section along the piping
system.
5.5.6 Arranging for safety and control devices
(recommended)
Avoiding contamination
1. Integrate filter into the suction pipe.
2. To monitor contamination, mount a differential pressure
gage with a contact manometer.
Avoiding reverse running
1. Install a check valve between the pressure socket and the
gate valve to ensure that the medium will not flow back
whenthepumpisswitchedoff.
2. To allow bleeding, provide a bleeding connection between
the pressure socket and the check valve.
Providing for isolating and shut-off devices for the pipes
For maintenance and repair work.
Provide for shut-off devices in the suction and pressure
pipes.
Allowing the measurement of the operating conditions
1. Provide for manometers for pressure measurements in
suction and pressure pipes.
2. Provide for motor-side torque measurement.
3. Provide for pump-side temperature measurement.
5.6 Connecting the pipes
5.6.1 Installing auxiliary pipes
Follow manufacturers' specifications of any existing auxil-
iary operating system.
1. Install auxiliary piping to auxiliary unions, ensuring stress-
free and sealed connections (→ Setup drawing).
2. To avoid air enclosures: run pipes with a continuous slope
up to the pump.
5.6.2 Installing the suction pipe
1. Remove transport and sealing covers at the pump.
2. To avoid air enclosures: run pipes with a continuous slope
up to the pump.
3. Ensure that no gaskets are protruding inwards.
4. For suction operation: Install a foot valve in the suction line
to prevent the pump and suction pipe from running empty
during downtime.
5.6.3 Installing the pressure pipe
1. Remove transport and sealing covers at the pump.
2. Mount the pressure pipe.
3. Ensure that no gaskets are protruding inwards.
18 NPC series BA-2005.07 EN – 02

Setup and connection
5.6.4 Inspection for stress-free pipe connections
✔Piping complete and cooled down
1. Separate the connecting flanges of the pipes from the
pump.
2. Check that pipes are freely moveable in all directions within
the range of expected expansions:
– nominal width < 150 mm : by hand
– nominal width > 150 mm : with short lever
3. Make certain that the flange surfaces are parallel.
4. Reconnect the connecting flanges of the pipes at the pump.
5.6.5 Inspecting the support foot for distortion
1. Loosen the bolts connecting the support foot to the base
plate.
2. If the support foot moves, compensate distortion:
– lateral shift: by means of slotted holes
– height shift: by means of metal shims
3. Tighten the support foot bolts in the base plate, making cer-
tain that the bearing bracket is not distorted in the process.
5.7 Electrical connection
DANGER
Risk of death through electric shock!
Have all electrical work carried out by qualified electricians
only.
DANGER
Risk of death due to rotating parts!
Isolate the motor from its supply voltage and keep it locked
in that state while carrying out any fitting or maintenance
work.
5.7.1 Connecting the motor
Follow the instructions of the motor manufacturer.
1. Connect the motor according to the connection diagram.
2. Make certain to prevent hazards due to electric energy.
3. Install an EMERGENCY OFF switch.
5.7.2 Checking the direction of rotation
DANGER
Risk of death due to rotating parts!
Use protective equipment when carrying out any work on
the pump.
Secure the key against being thrown off during the rotation
direction check.
Keep adequate distance to rotating parts.
CAUTION
Material damage caused by running dry and wrong direc-
tion of rotation!
Decouple the motor from the pump.
1. Switch motor on and immediately off again.
2. Check that the direction of rotation of the motor corre-
sponds to the rotational direction arrow on the pump.
3. If the direction of rotation is different: swap two phases.
4. Couple the motor to the pump.
EN – 02 BA-2005.07 NPC series 19

Setup and connection
5.8 Fine alignment of the coupling
DANGER
Risk of death due to rotating parts!
Isolate the motor from its supply voltage and keep it locked
in that state while carrying out any fitting or maintenance
work.
CAUTION
Material damage due to incorrect alignment of the cou-
pling!
If there is any height, lateral or angle misalignment, align
the motor exactly with the pump.
For detailed information and special couplings: (→ Manu-
facturers instructions).
Inspecting the coupling alignment
✔Implements, tools and materials:
– feeler gage
– hair ruler
– dial gage (can be used for coupling with a spacer piece)
– other suitable tools, e.g. laser alignment instrument
1
2
A
Fig. 13 Inspecting the coupling alignment
1. Measure in two planes at an angle of 90° to each other on
the circumference of the coupling.
2. Measure the light gap to the outer diameter with hair ruler
(1):
– Position the hair ruler across both halves of the cou-
pling.
– If there is a light gap at the outer diameter, align the
motor (→ 5.9 Aligning the motor, Page 20).
3. Measure the gap using feeler gage (2):
– Allowable gap (→ Setup drawing).
– Use the feeler gage for measuring gap width (A)
between the coupling halves.
– If the gap width is outside the allowable range, align
the motor (→ 5.9 Aligning the motor, Page 20).
Fig. 14 Inspecting for lateral and height misalignment
4. Inspect for lateral and height misalignments using the dial
gage:
– Carry out the measurement as shown in the figure.
– If there is any lateral or height misalignment, align the
motor (→ 5.9 Aligning the motor, Page 20).
Allowable axial or radial deviation, measured on the
coupling front or coupling circumference, respectively:
<0.05mm
Fig. 15 Inspecting for angle misalignment
5. Inspect for angle misalignment using the dial gage:
– Carry out the measurement as shown in the figure.
– If there is any angle misalignment: align the motor.
5.9 Aligning the motor
Alignment options:
– using sets of shims
5.9.1 Aligning the motor using sets of shims
1. Align the motor so that the coupling halves are exactly flush
with each other. Underlay with compensation shims where
necessary.
2. Check the alignment.
3. Repeat alignment procedure if there is still a height mis-
alignment.
4. Tighten the motor screws.
20 NPC series BA-2005.07 EN – 02