schmalenberger FZ Series User manual

Operator´s manual / installation instructions
GB
27215 - G.1
Translation of the original
Circulating pump
Typ Z, FZ, SZ, NZ, ZL, FZL, SZL, NZL,
ZB, FZB, SZB, NZB

2 Pump Typ Z
Version: 27215 -G.1
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
EU Declaration of Conformity
Manufacturer:
Schmalenberger GmbH + Co. KG
Strömungstechnologie
Im Schelmen 9-11
D-72072 Tübingen / Germany
The manufacturer hereby declares that the product:
Centrifugal pump type:
Z, FZ, NZ, SZ, ZL, ZB, FZL, FZB, NZL, NZB, SZL, SZB, SZcut (identification numbers: all)
Serial number range: 2018000001 - 2023999999
has been manufactured in accordance with the following directives:
Directive 2006/42/EC "Machinery"
The machine continues to comply with the provisions of the directives:
2014/34/EU - applies only to products with ATEX marking: 2G, 3G, 2D or 3D on the pump rating plate.
Standards that were used: EN 80079-36, EN 80079-37
Harmonised standards that were used:
EN 809+A1+AC, EN ISO 12100, EN 60034-1, EN 60034-5/A1, EN 60034-30-1
Authorised representative for the compilation of the technical documentation:
Marco Alber
Quality assurance
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
Phone [phone]
The EU Declaration of Conformity has been issued:
Tübingen, 10 April 2018
----------------------------------------------------
Thomas Merkle
Head of Development & Design
Schmalenberger GmbH + Co. KG

3
Pump Typ Z
Version: 27215 -G.1 Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
EU Declaration of Incorporation
Manufacturer:
Schmalenberger GmbH + Co. KG
Strömungstechnologie
Im Schelmen 9-11
D-72072 Tübingen / Germany
The manufacturer hereby declares that the product:
Centrifugal pump if delivered without drive, type:
ZB, ZL, FZB, FZL, NZB, NZL, SZB, SZL (identification numbers: all)
Serial number range: 2018000001 - 2023999999
an incomplete machine in accordance with Regulation 2006/42/EC Article 2g and provided exclusively for
assembly with another machine
which meets the following basic requirements of Regulation 2006/42/EC:
Appendix I, Article 1.1.1, 1.1.2, 1.1.3, 1.1.5.
Harmonised standards that were used: EN 809+A1+AC, EN ISO 12100
The machine continues to comply with the provisions of the directives:
2014/34/EU - applies only to products with ATEX mark 3G or 3D on the pump rating plate.
Standards that were used: EN 80079-36, EN 80079-37
The incomplete machine must not be placed in operation until it has been determined that the machine to be
installed in the incomplete machine is in compliance with the requirements of the Machinery Directive (2006/
42/EC).
Authorised representative for the compilation of the technical documentation:
Marco Alber
Quality assurance
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
Phone [phone]
The EU Declaration of Incorporation has been issued:
Tübingen, 10 April 2018
----------------------------------------------------
Thomas Merkle
Head of Development & Design
Schmalenberger GmbH + Co. KG

4 Pump Typ Z
Version: 27215 -G.1
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
Contents
1 General Details ................................................................................. 6
1.1 User Information .................................................................................................... 6
1.2 Usage Instructions ................................................................................................. 6
1.3 Relevant Documentation ....................................................................................... 6
1.4 Technical Data / Specifications ............................................................................. 7
2 Safety Instructions ........................................................................... 7
2.1 General .................................................................................................................. 7
2.2 Temperature .......................................................................................................... 8
2.3 Safety Instructions for Maintenance and Repairs .................................................. 8
3 Transport, Storage, Installation ...................................................... 8
3.1 Transport and Storage .......................................................................................... 8
3.1.1 Transport ............................................................................................................... 8
3.1.2 Storage .................................................................................................................. 8
3.1.3 Conservation ......................................................................................................... 9
3.2 Unpacking, Cleaning and Assembly ..................................................................... 9
3.2.1 Unpacking ............................................................................................................. 9
3.2.2 Cleaning ................................................................................................................ 9
3.2.3 Assembly ............................................................................................................... 9
3.3 Installing and Connecting .................................................................................... 10
3.3.1 Check before you start installing ......................................................................... 10
3.3.2 Installing the unit ................................................................................................. 10
3.3.3 Connecting the Pipework .................................................................................... 10
3.3.4 Electrical Connections ......................................................................................... 11
4 Operating the Pump ....................................................................... 12
4.1 Initial Start-up ...................................................................................................... 12
4.1.1 Starting the pump ................................................................................................ 12
4.2 Operating ............................................................................................................. 13
4.2.1 Operation Monitoring ........................................................................................... 13
4.2.2 Miscellaneous ...................................................................................................... 13
4.3 Indications of Faulty Operation ............................................................................ 13
4.3.1 General ................................................................................................................ 13
4.3.2 Faults ................................................................................................................... 13
4.4 Shutdown ............................................................................................................ 14
4.5 Fault Elimination .................................................................................................. 15

5
Pump Typ Z
Version: 27215 -G.1 Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
5 Maintenance / Repair .....................................................................17
5.1 Maintenance / Service .........................................................................................17
5.1.1 Checks ................................................................................................................. 17
5.1.2 Lubrication and change of lubricant .....................................................................17
5.2 Repair .................................................................................................................. 18
5.2.1 Dismantling Preparations .................................................................................... 18
5.2.2 Dismantling / Removal of the Pump .................................................................... 18
5.2.3 Dismantling / Dismantling the Pump .................................................................... 19
5.2.4 Dismantling the pump Type Z, FZ 4013, FZ 5016, SZ 2513, SZ 3216,
SZ 4013, SZ 5016 ............................................................................................... 19
5.2.5 Dismantling the pump Type NZ, FZ 6520 ............................................................20
5.2.6 Shaft sealing ring / throttling bush ....................................................................... 20
5.2.7 Pump re-assembly ............................................................................................... 20
5.2.8 Bearing support ................................................................................................... 21
6 Appendix .........................................................................................22
6.1 Shutdown / Storage / Conservation ..................................................................... 22
6.1.1 Storage of New Pumps ........................................................................................ 22
6.1.2 Longer Periods of Shutdown >3 months .............................................................22
6.1.3 Restarting after Periods of Storage .....................................................................22
6.2 Disposal ............................................................................................................... 22
6.3 Documentation for pump operation .....................................................................23
6.4 Data sheet ........................................................................................................... 23
7 Important Instructions ...................................................................23
7.1 Factory repair ...................................................................................................... 23
7.2 Ordering Spare Parts ........................................................................................... 23
8 Spare parts list and drawing ........................................................23
8.1 Type: Z, FZ 4013, FZ 5016, SZ 2513, SZ 3216, SZ 4013, SZ 5016, ZL, FZL 4013,
FZL 5016, SZL 2513, SZL 3216, SZL 4013, SZL 5016, ZB, FZB 4013, FZB 5016,
SZB 2513, SZB 3216, SZB 4013, SZB 5016 ....................................................... 26
8.2 Type: NZ, FZ 6520, NZL, FZL 6520, NZB, FZB 6520 .........................................29

6 Pump Typ Z
Version: 27215 -G.1
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
1 General Details
1.1 User Information
This operator’s manual makes it easier to
get to know the centrifugal pump and to
make full use of its facilities.
The operator’s manual contains important
instructions how to use the centrifugal
pump safely, properly and economically.
Your careful attention to these instructions
will help to avoid danger, to reduce repair
costs and breakdowns and to increase the
reliability and useful life of the centrifugal
pump.
The operator’s manual does not take
account of local regulations. The user is
responsible for ensuring that they are
complied with.
The label specifies the machine series, the
frame size, the most important operating
data and the serial number. We request
that you always quote it in case of queries,
when placing subsequent orders and
especially when ordering spare parts.
1.2 Usage Instructions
The centrifugal pump must only be used in
accordance with the original pump
specifications and the operator´s manual.
Any other usage or operation where these
figures are exceeded is not permitted. The
manufacturer is not liable for damage
resulting from such improper use.
The pump must only be operated in
applications that are described in the
relevant documents.
• The pump must only be operated if it is
in flawless technical condition.
• The pump must not be operated if it is
only partially mounted.
• The pump may only be used to convey
the media described in the data sheet
or in the documentation for the relevant
design.
• Never operate the pump without a pum-
ping medium.
• Pay careful attention to the information
in the data sheet or documentation re-
garding minimum delivery volume (to
prevent damage from overheating, da-
mage to the bearings, etc.).
• Pay careful attention to the information
in the data sheet or documentation re-
garding maximum delivery volume (to
prevent overheating, damage to the
mechanical seal, cavitation damage,
damage to the bearings, etc.).
• Do not throttle the pump on the suction
end (to prevent cavitation damage).
• Coordinate other types of operation
with the manufacturer if they are not ci-
ted in the documentation or data sheet.
Preventing foreseeable misuse
• Never open the pressure-end shut-off
elements beyond the permissible range
- Exceeding the maximum delivery vo-
lume cited in the data sheet or docu-
mentation is not permitted (possible
cavitation damage)
• Never exceedthepermissible operating
limits cited in the data sheet or docu-
mentation in terms of pressure and tem-
perature, etc.
• Comply with all safety instructions and
directions in this operator's manual.
1.3 Relevant Documentation
Various documents are associated with
every centrifugal pump that comprise the
technical documentation of the pump.
These are as follows:
• Specification with all data
• Operator’s manual
• Declaration of conformity / Declaration
of Incorporation
• Drive operator’s manual
• Declaration of conformity with supple-
ment BA for ATEX-pumps

7
Pump Typ Z
Version: 27215 -G.1 Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
• Manual for accessories listed in the
specifications manual
• Pilot run report
• Performance run report
• Dimensions sheet
• Acceptance report from the TÜV (Tech-
nical Certification Authority) etc.
Not all the above documentation has been
produced and supplied in every case. For
this please check the details in the
specification.
1.4 Technical Data /
Specifications
The specifications of the centrifugal pump
is the most important document in every
operator’s manual. Contained therein are
all the relevant and technical data relating
to the centrifugal pump. It is the birth
certificate of the centrifugal pump and
should be treated accordingly.
As a substitute the order confirmation
together with the delivery schedule may
also be a source of technical data.
2 Safety Instructions
2.1 General
It is essential that the relevant safety
regulations and laws that apply in the
operating company and / or country where
the pumps are to be used are observed .
In this operating manual the following
symbols are used to draw your attention to
sources of danger. The symbols are
intended to attract your attention to these
instructions!
Symbol Meaning:
Notices attached directly to the pump, e.g.
arrows indicating direction of rotation and
the marking for fluid connections, must
always be observed and maintained in a
clearly legible condition.
- Use the pump only if it is in perfect tech-
nical condition, in accordance with the re-
gulations, observing safety requirements
and danger conditions and strictly adhe-
ring to all the instructions in the operator’s
manual!
- Promptly remedy any faults that could in-
fluence safety.
-Prior to starting up, make sure that the
operators have read and understood
the operator’s manual. Not the operator
but the owner is responsible for safety!
- The centrifugal pump is designed to be
built into a total machine or plant.
- Leaks of hazardous delivery media, (e.g.
explosive, poisonous, hot) must be con-
trolled so that no danger occurs to per-
sons or the environment. Comply with
legal requirements.
Attention! Danger of injury!
This sign warns you of the dan-
ger of mechanical effects.
Warning! Mortal danger!
This sign warns you of the dan-
ger from electric shocks.
Information:
It also instructs you in the eco-
nomic use of the pump.
Attention!
The centrifugal pump is
delivered without a contact
safety device.
When the pump is installed in
the system, the system
manufacturer must attached
the contact safety device for
hot, cold and moving parts on-
site and check its function.
Do not remove the contact
safety device during operation!

8 Pump Typ Z
Version: 27215 -G.1
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
- Danger from electric shocks must be
completely excluded (for details see the
country specific regulations and / or those
of the local power supply company).
- Electrical equipment must be installed
and maintained exclusively by qualified
electricians in accordance with regulati-
ons VDE or IEC.
- Before switching on or starting up the
centrifugal pump, make sure that no-one
will be endangered by the start-up of the
pump!
2.2 Temperature
2.3 Safety Instructions for
Maintenance and Repairs
- Regardless of what nature they may be,
repairs must only be carried out by quali-
fied persons and the centrifugal pump
must be emptied first.
- The attached pipework must be depres-
surized.
- Allow the pump to cool off.
- Prior to carrying out repairs to the pump it
must be isolated from the electrical sup-
ply and protected from unintentional swit-
ching on.
3 Transport, Storage,
Installation
3.1 Transport and Storage
3.1.1 Transport
Pumps that are designed to be built into
containers must be transported lying down!
The eyebolts on the motor are designed to
carry only the weight of the motor. To lift the
combined motor and pump aggregate
suitable attachments must be made so that
both units are catered for! If necessary the
centre of mass is indicated on the pump
unit and on the packing material, and
places for applying lifting hooks are
marked.
Hoisting examplefor pumps designed to be built into
containers
3.1.2 Storage
- Interim storage
Even for short periods of interim storage,
store on a wooden base in a dry, well
ventilated and vibration free environment at
constant temperature.
Important:
The centrifugal pump must be
immediately stopped if
abnormal electrical voltages,
temperatures, noises,
vibrations, leakages or other
faults should arise.
Warning! / Danger of burns!
The centrifugal pump housing
gets hot during operation. If the
temperature rises to over
+50°C, the centrifugal pump
must be protected from direct
contact by the operator.
Attention! Danger of injury!
Use only suitable and
technically perfect lifting and
load-bearing equipment with
sufficient carrying power!
Never stand or work
underneath swinging loads!

9
Pump Typ Z
Version: 27215 -G.1 Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
- Unsuitable storage
If unsuitable storage conditions prevail
(e.g. high humidity) or if the pump is to be
stored for longer than 6 weeks, then the
pump housing should be filled with oil (see
chapter 3.1.3.).
- Long periods of storage
After a storage period of more than 2 years
the motor roller bearings and bearing
supports need to be re-greased or replaced
entirely.
3.1.3 Conservation
The centrifugal pumps that we deliver are
treated with a conservation material
corresponding to the storage time quoted
us by the purchaser. This conservation
must be removed before start-up. See
chapter 3.2.2 “Cleaning”.
If the pump is to be taken out of service for
a longer period of time or if the originally
envisaged storage time is going to be
considerably exceeded, then conservation
must be undertaken as protection against
corrosion.
How to do this is described in detail in
chapter 6.1 “Shutdown and Storage”.
3.2 Unpacking, Cleaning and
Assembly
3.2.1 Unpacking
For transportation purposes the pump is
fastened to a palette by bands. For
transportation over long distances it is
packed in crates or boxes .
After removing the retaining bands extract
the pump out of its packing with the help of
suitable lifting equipment. Observe the
instructions in section 3.1.1.
3.2.2 Cleaning
A number of measures are taken for
protection against transportation damage
and corrosion. Check your pump for which
measures have been taken.
1. Covering lid on the nozzles
2. Shaft protection for deliveries without
the motor
3. Protective paint on exposed parts.
These protective measures must be
removed before the pump is set up or
installed. Under no circumstances must
impurities be left inside the pump.
3.2.3 Assembly
In general the pump is delivered fully
assembled and can be installed directly.
In special cases the pump is delivered
without the drive motor. Prior to installing
the pump in the plant, install the drive motor
into the pump.
Important:
Depending on the delivery medi-
um to be used, the interior of the
pump should be cleaned of resid-
ual traces of oil. Use a cleaning
agent that will not be harmful to
the throttling section and pump
materials. Make sure that the
pump is carefully dried after
cleaning.
The cleaning agents that can be
used include spirit, Ritzol 155 or a
strongly alkaline soap solution, for
example. If a steam jet cleaner is
to be used, then let the solvent
work itself in for a time first. Then
also please take care not to dam-
age the electric motor and bear-
ings.
Important:
Before installation check that the
pump runs freely and easily.

1 0 Pump Typ Z
Version: 27215 -G.1
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
Other external accessories, such as a blast
tank or similar equipment, that have not
been assembled with the pump at the
factory, should be mounted on the pump
after it has been installed in the system or
on the pump base.
3.3 Installing and Connecting
3.3.1 Check before you start
installing
• Have the machine, the system and the
container nozzles been properly prepa-
red in accordance with the figures on
the dimensions sheet or installation
plan?
• Has the concrete base got adequate
strength (minimum of B 15) in accor-
dance with DIN 1045?
• Is the concrete base hydrated?
• Is the surface level and even?
3.3.2 Installing the unit
These centrifugal pumps must only be
installed in a vertical position.
Except for special models, the pumps are
always placed on the cover plate (base
plate) and fastened down by screws.
When installed on a foundation the
centrifugal pump must be set up with the
aid of a spirit level.
3.3.3 Connecting the Pipework
In the case of pipework the nominal bore
should be at least the same as the pump
connections.
Connection pieces to larger nominal bores
should be carried out with approx. 8°
expansion angle to avoid significant loss of
pressure.
The suction pipe to the pump must be
installed to rise continuously, on the
pressure side it must fall continuously.
Safety Instructions /
Explosion proof
Pay particular attention to the
Supplementary operator's
manual "explosion protection"
Warning!
Stability, Danger of injury!
Pumps with a motor at the top
are very top heavy. These
pumps must be safeguarded
against tipping up during
installation or removal e.g. with
the help of ropes.
Caution!
Never install the pump with the
„motor below“.
Warning!
Under no circumstances must
the pump be used as anchor
point for the pipework. No
forces or moments (e.g. due to
twisting or heat expansion)
from the pipework must act on
the pump. The pipes must be
supported as close as possible
to the centrifugal pump and
connected to it free of all
tension.

11
Pump Typ Z
Version: 27215 -G.1 Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
Depending on the type of system and pump
being used, it is recommended that
backflow prevention and shut-off devices
are installed.
Expansion of the pipes due to temperature
must be remedied by suitable measures.
We recommend the installation of
compensators in the pipeline.
Valves that close very suddenly (abruptly)
must be avoided in the pipework. The
resulting pressure surges can greatly
exceed the maximum permitted housing
pressure of the pump! To prevent too
strong pressure surges dampers or blast
tanks should be installed .
Often welding beads, scales and other
impurities do not get dislodged for some
period of time. They should be kept clear of
the pump by inserting a sieve in the suction
pipe. The free cross-section of the sieve
must be 3 times the cross-section of the
pipe so that there is not too large a
resistance built up due to foreign bodies
that flow in. Hat-shaped sieves containing a
mesh wire net having a mesh size of 2.0
mm and 0.5 mm wire diameter made of
corrosion resistant material have proved
useful in practice.
3.3.4 Electrical Connections
The electrical connections to the pump
must be carried out by a specialised
company in the electrical engineering
branch approved by the local energy
provider, taking into account the technical
connection requirements.
The connections must be carried out by a
qualified electrician.
The relevant DIN VDE (Association of
German Engineers) regulations must be
observed.
Compare the available power supply
voltage with the details on the motor’s
factory plate and select the appropriate
switching.
We recommend the use of a motor
protection facility.
In compliance with VDE 0530-8, three-
phase motors are always wired for
clockwise rotation (looking at the motor
shaft stub).
The direction of rotation of the pump is anti-
clockwise as standard (viewed from the
suction flange).
Always note the arrow on the pump
indicating the direction of rotation.
Connect the motor according to the circuit
diagram in fig. 1 or fig. 2.
Delta connection (low voltage)
Fig. 1 Connection for 3-phase motors,
connection 
Important
Pipe compensators must not
be used to make up for
inaccuracies in the pipelines,
for example with a centre offset
of the flange.
Information:
At the end of installation, before
starting up the system the
containers, pipes and
connections must be
thoroughly cleaned, rinsed and
blown through.
Risk of explosion!
Where there is a risk of
explosion a motor protection
device must be fitted!
W2 U2 V2
U1 V1 W1
L2 L1 L3

1 2 Pump Typ Z
Version: 27215 -G.1
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
Star connection Y (high voltage)
Fig. 2 Connection for 3-phase motors,
connection Y
Motor with PTC thermistors as thermal
winding protection
Connect the PTC thermistor (PTC sensor)
to the downstream trigger unit if required.
The PTC thermistors are designed
according to DIN 44081 and DIN 44082.
Time relay setting
For three-phase motors with star-delta
connection it must be ensured that the
switching points between star and delta
follow each other very rapidly. Long
switching times can result in damage to the
pump. Setting of the time relay for star-
delta connection: < 3 sec.
Direction of rotation check
The direction of rotation of the motor must
agree with the direction of the rotation
arrow on the motor housing of the pump
(seen from the motor, in a clockwise
direction). Check by rapidly switching on
and off.
If the direction of rotation is wrong, change
any two phases L1, L2 or L3 of the power
supply in the motor terminal box over.
Additional motor equipment
If particular control devices are to be used
e.g. in connection with the installation of the
pump in a process engineering facility, the
instructions of the manufacturer of the
control devices must be strictly observed.
4 Operating the Pump
4.1 Initial Start-up
4.1.1 Starting the pump
Make sure that the shut-off device on the
pressure end is half open before starting
the pump up! Once the maximum rotation
speed has been reached, slowly open it up
and adjust to full operational level.
W2 U2
U1 V1 W1
L2 L1 L3
V2
Warning!
Prior to initially starting up the
pump please make sure that
the following prerequisites
have been met:
1. The pump has been
connected properly
electrically and with all
requisite safety features.
2. The pump is filled with
delivery medium or there is
a minimum level of fluid in
the tank / pool (pump is
covered).
3. Please observe: Running
dry creates increased wear
and must be avoided at all
costs!
4. The rotating parts of the
pump have been covered
by a protective shield. (In
accordance with UVV
(Accident Prevention
Regulations) the centrifugal
pump may only be operated
if a safety shield has been
fitted).
5. The pump shaft turns
easily.
6. The direction of rotation has
been checked.
7. The minimum distance
between the suction inlet
and tank wall is 150 mm.

13
Pump Typ Z
Version: 27215 -G.1 Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
4.2 Operating
4.2.1 Operation Monitoring
In most cases the pump is controlled from
the central point of the overall facility. A
prerequisite for a perfectly functioning
pump is adherence to the data provided for
its installation and use. See the chapter on
specifications.
1. Temperature of the delivery fluid: -
Never operate the pump at
temperatures in excess of those stated
in the original specification.
2. Noise emission: - The acoustic power
or sound pressure level is determined
by the motor as well as the pump, and
especially by the installation situation.
Special protective measures must be
taken to reduce transmission of
structure-borne or air-borne sound.
3. Switching frequency: - To avoid a
large temperature increase in the motor
and excessive strain on the pump, the
motor and bearings, do not switch the
motor on and off more than once per
minute.
4. Minimum amount: - If the sort of
facility includes the possibility of a run
against closed shut-off device on the
pressure-end, a minimum delivery rate
at t -30 to +70° C 15% of Qopt. over
+70 to +110° C 25% of Qopt. must be
supplied during this time.
5. Density of the delivery fluid: - The
power input of the pump changes in
proportion to the density of the delivery
fluid. In order to prevent the motor being
overloaded, the density must
correspond to the specifications.
4.2.2 Miscellaneous
Installed reserve pumps must be run briefly
once a week to ensure that they are always
ready for operation. They should be run for
approx. 5 minutes.
4.3 Indications of Faulty
Operation
4.3.1 General
When operated via a central control facility
faulty operation can be largely ruled out.
In the case of manual operation, but also
within a control complex, please observe
the following instructions.
Avoid damage to the pump and make sure
that:
• The pump always runs quietly and
vibration free.
• The pump does not run dry.
• A longer period of operation with closed
shut-off device is avoided to prevent
heating up the delivery medium. For the
required minimum delivery see section
4.2.1.
• The maximumpermitted roomtempera-
ture of +40° is not exceeded.
• The maximum ball bearing temperature
does not exceed
room temperature by + 50° C and ne-
ver exceeds + 90° C (measured on the
outside of the motor housing).
• During pump operation the shut-off de-
vice in the supply line is not closed.
4.3.2 Faults
In case of faults in the operation of the
pump, that were not caused by the control
facility or other foreign devices, proceed as
follows:
1. Locate the site of the fault or defect.
2. Determine the cause.
3. Remedy the fault.
Information:
Pay particular attention to the
following points for the manual
operation of the pump:

1 4 Pump Typ Z
Version: 27215 -G.1
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
In chapter 4.5 “Fault Elimination” there is
a table listing the most frequent faults, their
cause and the recommended way to
eliminate them.
4.4 Shutdown
1. Close the shut-off device in the
pressure pipe. If backflow prevention is
fitted to the pressure pipe the shut-off
device can remain open, provided that
there is back pressure.
2. Switch motor off. Allow it to come to
rest. Depending on the sort of facility,
the pump should be allowed sufficient
idle run time – with the heat source, if
any, switched off to allow the delivery
fluid temperature to reduce – to prevent
an accumulation of heat within the
pump
.
Warning!
If there is a danger that the
pump may freeze and / or for
occasions where it is to be at a
standstill for longer periods of
time, the pump must be
emptied or protected against
freezing up (by auxiliary
heating).

15
Pump Typ Z
Version: 27215 -G.1 Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
4.5 Fault Elimination
Table 1: The causes and elimination of faults
Pump stands still too little delivery rate from pump motor overload too low pump pressure too high pump pressure high motor / bearing temperature pump leaks pump runs noisily, running noises pump temperature too high
Cause of the fault Elimination of the fault
xx Back pressure too high, pump is deli-
vering against too high a pressure,
system resistance too great, pipe too
small
Set new operating point, system dirty,
increase rotation speed, install a new
impeller, clean pipes, increase pipe
size, install larger pump
xx x Pump / pipework not completely ven-
ted, air suction through too small a
covering, gas build-up, air bubble in
the pipework, high percentage of air in
the medium, supply or impeller bloc-
ked.
Increase fluid level, correct level con-
trol, install pump lower down, vent the
system, clean pipework, change pipe-
work, de-gas the medium, decrease
resistance in the supply pipe, fully
open valves in the suction pipe, clean
sieves and suction connections, install
a relief valve directly in front of the
non-return valve.
xx Wrong phase sequence, wrong electri-
cal connections, rotation speed to low,
gap between wearing plate and open
impeller too large, air entering via the
throttling section
Change over two of the phases in the
terminal box, increase rotation speed
(*) (if necessary, get new motor),
decrease the gap between wearing
plate and open impeller, renew thrott-
ling section, install pump lower down
or increase fluid level
xx
Worn internal parts (e.g. impeller) Remove foreign body from pump
housing, replace worn parts, renew
throttling section
xx Pump back pressure is lower than sta-
ted in the specifications, electrical
connections wrong
Set operating point precisely, increase
back pressure e.g.: by throttling the
pump on the pressure side, perhaps
turn off impeller (*), larger motor (*),
compare electrical connections with
those on the motor rating plate;
observe circuit diagram in chapter
3.3.4
xx Higher density or greater viscosity of
the delivery medium than in the speci-
fications
New pump correlation (*)
xCavitation Throttle pump on pressure side, larger
pump (*)
xSystem resistances too low, manome-
ter defective Increase back pressure, e.g. by thrott- ling the pump on the pressure side,
larger pump (*), larger impeller (*)

1 6 Pump Typ Z
Version: 27215 -G.1
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
(*) Please contact the manufacturer
xForeign body in the pump, throttling
section worn, motor bearings defec-
tive, safety switch was triggered due to
motor overload, safety switch too
small, winding defective
Remove foreign body from the pump
housing, clean or change pump
housing, renew throttling section,
renew motor bearings, check electrical
connections / compare to motor
ratings plate, throttle pump, smaller
impeller (*), larger motor (*)
xx Impeller imbalanced, bearing defec-
tive, too little / too much or wrong lubri-
cant
Clean impeller, balance the impeller
(*), renew bearings, add / decrease or
completely change the lubricant
xx Coupling distance not maintained,
pump wrongly adjusted, pump distor-
ted or resonance vibrations in the pipe-
work, several pumps on one console,
increased axial thrust
Set correct distance, adjust pump cor-
rectly, check pipework connections /
pump mountings, single pump setting,
connect pipework via compensators,
install vibration damper under the
pump, stiffen the tank, clean relief
bores in the impeller
xRotation speed to high, pump too large
(wrong design) Decrease rotation speed, smaller pump (*), turn off impeller (*)
xPump delivery too small, pipework
blokked, closed valve on pressure side Re-set pump, install a bypass for low volume requirements, clean pressure
pipe, switch pump on only when requi-
red, pump must not run too long
against closed valve;
no reduction in temperature: use a
smaller pump (*)
xGaskets defective, pump badly adju-
sted, throttling section defective Renew gaskets, adjust pump preci- sely, check pipework connections,
renew throttling section.
Table 1: The causes and elimination of faults
Pump stands still too little delivery rate from pump motor overload too low pump pressure too high pump pressure high motor / bearing temperature pump leaks pump runs noisily, running noises pump temperature too high
Cause of the fault Elimination of the fault

17
Pump Typ Z
Version: 27215 -G.1 Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
5 Maintenance / Repair
General Instructions
The operator must ensure that all
maintenance, service and repair work on
the pump is carried out exclusively by
authorised and specially trained persons. It
must be established beyond doubt that the
person has studied the operator’s manual
in detail.
We recommend the creation of and
adherence to a maintenance schedule.
That will enable you to avoid expensive
repairs and have a reliable and trouble-free
pump operation.
Only original spare parts must be used for
repairs.
If work has to be carried out on the motor
the instructions in the manual from the
relevant motor manufacturer must be
observed.
5.1 Maintenance / Service
Use the following information to create a
maintenance schedule. These are
recommendations of minimum
requirements that must be adjusted to local
conditions of use of the pump and may
need amending accordingly.
5.1.1 Checks
Continuous checks:
• Pump delivery data (pressure, amount)
•Powertake-up
Daily checks:
• Pump running is quiet and vibration free
• Bearingtemperature (see section 4.3.1)
More frequent monitoring must be planned
for liquids with properties that differ greatly
from those of water (which tend to stick or
form accumulations, for example, or have a
high gas content).
Smooth operation of the shaft may be
impaired for example by accumulations or
sticks. If this happens, smooth operation
must be restored before starting up. See
section 6.1.3 "Restarting after Periods of
Storage".
Monthly checks:
• Wear on the coupling (elastic compo-
nent)
• Screws are tight
5.1.2 Lubrication and change of
lubricant
Pumps in their standard models only have
bearings in the drive motor. In the models
with IEC motor and intermediate stub the
bearings in the intermediate stub are filled
with a grease that cannot be replenished.
This grease lasts for the working life of the
unit and cannot be replenished. Defective
bearings must be replaced.
Bearings in larger motors must be
relubricated on a regular basis. See also
the "Operator's Manual for Pump Drives" in
section 6.2 "Motor Bearings".
Mortal danger!
In order to prevent electric
shocks, work on the terminal
box and the machine controller
must never be carried out
before the electrical
connections have been
isolated or disconnected.
Attention! Danger of injury!
Mortal Danger!
The pump must be
safeguarded against
unintentional switching on (be
disconnected) if checking or
maintenance work is to be
undertaken.

1 8 Pump Typ Z
Version: 27215 -G.1
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
5.2 Repair
General
Always carry out repair work on the
removed pump in an appropriate
workshop.
Be sure to observe the general instructions
at the beginning of the chapter!
The following instructions will enable you to
dismantle the pump and to re-assemble it
properly with the requisite spare parts in
place.
The work can be undertaken with the usual
workshop tools. Special tools are not
required, with the exception of for the
installation of a new throttling bush.
After dismantling, thoroughly clean all the
individual parts of the pump. Check the
individual parts for wear and damage. Parts
that are not perfect must be reworked or
replaced.
5.2.1 Dismantling Preparations
When used in a facility, inform the shift
leader or manager.
5.2.2 Dismantling / Removal of the
Pump
The pump must be allowed to reach room
temperature.
• Disconnect the power supply.
• Close valves (on the suction and pres-
sure sides).
• Remove existing additional connecti-
ons.
• Release pressure and suction nozzles.
• Disconnect motor.
• Release pump base plate
• Completely lift out the pump (out of the
tank, etc.)
• Empty the pump
When emptying the pump please observe
the following instructions!
Information:
Also take note of the exploded di-
agram in chapter 8 “Spare parts
list / Drawing”.
Important:
Priorto starting to dismantleit the
pump must be safeguarded
against accidental switching on
(it must be disconnected). Warn-
ing on the switching cabinet!
Important:
For the following work, please be
sure to observe local regulations
and conditions.
Warning!
1. If the pump was used to
deliver liquids that are
hazardous to health, then
great care must be taken in
emptying the pump that
neither persons nor the
environment are placed at
risk through the process.
2. If necessary, wear
protective clothing and
protective mask!
3. The rinsing liquid used and
any residual fluid out of the
pump must be caught and
disposed of properly and
without placing persons or
the environment in any
danger.

19
Pump Typ Z
Version: 27215 -G.1 Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
5.2.3 Dismantling / Dismantling the
Pump
Before you begin
Begin the work only once you have
checked that:
• The required spare parts are available
and that they will fit this pump or your
particular model thereof. Make sure that
in your spare parts order the pump seri-
al number was quoted.
• You have all the required tools and ac-
cessories for the work.
Observing these instructions is a
prerequisite for trouble-free operation of
the pump and for the acceptance of
potential claims under guarantee.
5.2.4 Dismantling the pump Type Z,
FZ 4013, FZ 5016, SZ 2513,
SZ 3216, SZ 4013, SZ 5016
Step 1:
Unscrew the spiral housing mounting
screws pos. 901.1 and remove the spiral
housing pos. 102. Remove the from the
connecting piece pos. 145 and pull off the
pressure pipe pos. 710. Now remove the
two round gaskets pos. 412.
Step 2:
Unscrew and remove the impeller nut pos.
922 and the distance washer pos. 554.01.
Now you can pull off the impeller pos. 233
and remove the key pos. 940.
Step 3:
Dismantle the connecting piece pos. 145
with the hexagon socket screws pos. 914.
Now you can pull off the connecting piece
pos. 145 together with the cover plate pos.
167.
Then take the protective shaft sleeve pos.
524 from the motor shaft pos. 818.
Make sure that for the dense shaft bushing
(DWF) that the connecting piece pos. 145
is pulled off together with the shaft sealing
ring pos. 420.
Now remove the counter ring pos. 475.
Step 4:
The throttling bush pos. 542 is glued into
the connecting piece pos. 145. Dismantle
thethrottlingbushonlyifitistobereplaced.
The replacement is described in chapter
5.2.6.
4. Pumps that deliver liquids
that are hazardous to
health must be
decontaminated. In
draining the delivery
medium off care must be
taken that neither persons
nor the environment are
placed in any danger.
5. Legal requirements must
be adhered to!
Information:
Use only original spare parts
for the repairs!
During re-assembly all the gas-
kets must be renewed.
Information:
For the SZ model you first have
to unscrew the hexagon socket
screws pos. 914 from the wear-
ing plate in order to be able to re-
move the wearing plate pos. 164.
When re-assembling install new
gaskets and a new wearing plate.

2 0 Pump Typ Z
Version: 27215 -G.1
Schmalenberger GmbH + Co. KG
D-72072 Tübingen / Germany
5.2.5 Dismantling the pump Type
NZ, FZ 6520
Step 1:
Unscrew the hexagon screws pos. 901.04
out of the pressure pipe and remove them.
Now remove the hexagon nut pos. 920.05
from the spiral housing. Lift the spiral
housing pos. 102 off.
Now you can remove the two clamp
gaskets pos. 400.01 and 400.02.
Step 2:
Unscrew and remove the impeller nut pos.
922 and the distance washer pos. 554.01.
Now you can pull off the impeller pos. 233
and remove the key pos. 940.
Step 3:
Dismantle the pressure cover pos. 163 by
unscrewing the hexagon nut pos. 920.06
and remove the protective shaft sleeve
pos. 524.
Make sure that for the dense shaft bushing
that you take off the shaft sealing ring pos.
420.
Remove the intermediate piece pos. 132.
By unscrewing the hexagon screws pos.
901.01 on the motor flange and the
transition piece pos. 721, you can remove
the intermediate piece together with the
cover plate pos. 167 and the pressure pipe
pos. 710.
Step 4:
The throttling bush pos. 542 is glued or
pressed into the throttling bush holder pos.
542. The throttling bush holder is glued into
the pressure cover pos. 163. Dismantle the
throttling bush only if it is to be replaced.
The replacement is described in chapter
5.2.6.
5.2.6 Shaft sealing ring / throttling
bush
With the delivery of a new throttling bush
you will receive fitting instructions (AA-
18003) how to install it correctly in your
centrifugal pump.
To fit the throttle bush you need a special
centring tool that may be ordered from the
manufacturer.
5.2.7 Pump re-assembly
Re-assembly is basically in the reverse
order to dismantling.
Observe the following preparatory steps:
• Thoroughly clean all individual parts of
dirt and residual glue (throttling bush
seating).
• Inspect all parts for wear and be sure to
replace any that are worn or damaged.
• Clamp gaskets and O-rings must al-
ways be replaced by new ones. Grease
O-rings prior to installation.
• If a new throttling bush made of silicon
carbide (SiC/SiC) was glued in place,
then the glue must be allowed to harden
for approx. 24 hours before assembly
can proceed. See assembly instructi-
ons (AA-18003). Make sure that this
period of time is observed!
Information:
When re-assembling install new
gaskets.
Information:
The throttling bushes built used
in the centrifugal pumps are not
wear-free.
Warning!
When dismantling the pump in-
spect the throttling bush and pro-
tective shaft sleeve for damage.
Be sure to replace a damaged
throttling bush and / or protective
shaft sleeve.
Important:
Never use a throttling bush you
have made yourself! We can ac-
cept no liability.