Seepex BTVE 10-12 Product guide

Not Binding Operating
and Assembly Instruction
Progressive Cavity Pump
This operating and assembly instruction is only
for general information.
Type
BT9(XSWR
Issue 27.08.2018

Index
Index
Index
Index
1
1
1
1 Safety
Safety
Safety
Safety....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................1
1
1
1
1.1 General notes
1.2 Safety and warning notes
1.2.1 Warning notes
1.2.2 Danger symbols
1.2.3 Information symbols
1.3 Dangers that can be caused by the machine
1.4 Qualification of the personnel
1.5 Authorised people
1.5.1 Tasks and information for the owner/operators
1.5.2 Safety notes for maintenance, inspection and assembly work
1.6 Personal protective equipment
1.7 Safety and protective devices
1.8 Foreseeable misuse
1.9 Designated use
1.10 Warranty
1.11 Safety clearance ...................................................................................................................... 5
1.11.1 General information
1.11.2 Safety clearance application area
1.11.3 Definition
1.11.4 Values for safety clearance
1.11.5 Reaching across protective constructions
1.11.6 Reaching around / through openings
1.12 Separating protective device
1.12.1 Pump with hopper extension (AST), technical service shutter (KIS) and safety switch
1.12.2 Pumps with cleanout
1.12.3 Pump with lid
1.13 Filling level hopper
2
2
2
2 Description of the pump
Description of the pump
Description of the pump
Description of the pump........................................................................................................................
........................................................................................................................
........................................................................................................................
........................................................................................................................9
9
9
9
2.1 General description
2.2 Mode of action and pumping principle of the pump
2.3 Constructive design
3
3
3
3 Technical Data
Technical Data
Technical Data
Technical Data....................................................................................................................................
....................................................................................................................................
....................................................................................................................................
....................................................................................................................................10
10
10
10

Index
Index
Index
Index
4
4
4
4 Transport, Intermediate storage, Disposal
Transport, Intermediate storage, Disposal
Transport, Intermediate storage, Disposal
Transport, Intermediate storage, Disposal..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................12
12
12
12
4.1 Safety
4.2 Transport
4.2.1 Dimensions, weight and centre of gravity
4.2.2 Symbol
4.2.3 Lashing points (AP) for lifting devices
4.2.4 Unpacking the machine
4.3 Temporary storage/corrosion protection
4.4 Disposal
5
5
5
5 Assembly / Installation
Assembly / Installation
Assembly / Installation
Assembly / Installation........................................................................................................................
........................................................................................................................
........................................................................................................................
........................................................................................................................ 15
15
15
15
5.1 Mounting tools / lifting gear
5.2 Space requirement
5.2.1 Dimension for stator replacement
5.3 Assembly of the complete mounted pump
5.4 Power supply of the pump
5.5 Pipelines
5.5.1 Suction and pressure connection
5.5.2 Pipeline dimensions
5.5.3 Residue-free pipelines
5.5.4 Tension-free assembly
6
6
6
6 Commissioning / De-Commissioning
Commissioning / De-Commissioning
Commissioning / De-Commissioning
Commissioning / De-Commissioning..................................................................................................
..................................................................................................
..................................................................................................
..................................................................................................17
17
17
17
6.1 Commissioning report............................................................................................................ 17
6.2 Measures before commissioning............................................................................................ 18
6.2.1 Checking pipelines
6.2.2 Protective devices on the pump
6.2.3 Electrical / hydraulic connections
6.2.4 Direction of rotation check
6.2.5 Additional devices - optional
6.3 Initial commissioning/repeated commissioning
6.3.1 Avoiding dry running of the pump
6.3.2 Pressure in the suction and pressure connection
6.4 De-commissioning
6.4.1 Switching off the pump
6.4.2 Emptying the pump
6.4.3 Dismantling the pump
6.4.4 Preservation/storage of the pump

Index
Index
Index
Index
7
7
7
7 Maintenance
Maintenance
Maintenance
Maintenance.......................................................................................................................................
.......................................................................................................................................
.......................................................................................................................................
....................................................................................................................................... 23
23
23
23
7.1 Preventative measures
7.1.1 Pump down-time
7.2 Lubrication
7.2.1 Joint grease
7.3 Inspection
8
8
8
8 Malfunctions, causes, rectification
Malfunctions, causes, rectification
Malfunctions, causes, rectification
Malfunctions, causes, rectification......................................................................................................
......................................................................................................
......................................................................................................
...................................................................................................... 25
25
25
25
9
9
9
9 Pump Dismantling / Reassembly
Pump Dismantling / Reassembly
Pump Dismantling / Reassembly
Pump Dismantling / Reassembly........................................................................................................
........................................................................................................
........................................................................................................
........................................................................................................27
27
27
27
9.1 Pump Dismantling / Reassembly........................................................................................... 27
9.1.1 Prepare the pump for dismantling
9.1.2 Dismantling
9.1.3 Reassembly
9.2 Rotating unit – individual parts .............................................................................................. 33
9.2.1 Dismantling
9.2.2 Rotating unit (RTE) - prepare individual parts for reassembly
9.2.3 Rotating unit (RTE) - individual parts - reassembly
9.3 Holding band - assembly........................................................................................................ 38
9.3.1 Prepare the holding band
9.3.2 Check the holding band
9.3.3 Assembling the holding band
9.3.4 Correct tension for the holding band (HBD)
9.3.5 Cant up the holding band
9.3.6 Shear the holding band
9.3.7 Check the holding band after assembly
9.4 Shaft seal ............................................................................................................................... 41
9.4.1 Safety
9.4.2 Application conditions and material version
10
10
10
10 Spare parts
Spare parts
Spare parts
Spare parts.........................................................................................................................................
.........................................................................................................................................
.........................................................................................................................................
.........................................................................................................................................

10.1 Order template for spare parts...............................................................................................
11
11
11
11 Special tools
Special tools
Special tools
Special tools.......................................................................................................................................
.......................................................................................................................................
.......................................................................................................................................
...................................................................................................................................
12
12
12
12 Related documents
Related documents
Related documents
Related documents.............................................................................................................................
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......................................................................................................................
13
13
13
13 Appendix
Appendix
Appendix
Appendix..........................................................................................................................................
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.........................................................................................................................................
...................................................................................................................................
13.1 Manufacturer's documents / suppliers
Subsidiaries

1
Ausgabe
issue D / 06.01.2014 Dokument document OM.SAF.01e Blatt sheet 1 (4)
1
Safety
1.1 General notes
¾Always keep the operating and maintenance instructions close by the machine.
¾If problems cannot be solved with reference to the operating and maintenance instructions,
please contact the manufacturer.
Observe the following points in addition to these operating and maintenance instructions:
• Prohibition, warning and mandatory signs, warning notes on the machine
• Relevant laws and ordinances
• Statutory provisions on accident prevention
• Corresponding harmonised standards and regulations
1.2 Safety and warning notes
¾Comply with safety and warning notes for safe and efficient use of the product.
Signal words for specific dangers and (possible) consequences are explained below. These
are supplemented by symbols (pictograms) if necessary.
1.2.1 Warning notes
1.2.2 Danger symbols
NOTICE
Caution for machine!
Possible danger.
Material damage can occur.
CAUTION
Caution for people and machine!
Possible danger.
Minor injury or damage to property can occur.
WARNING
Warning for people!
Possible danger.
Death or serious injury can occur.
DANGER
Danger for people!
Possible danger.
Immediate risk of sever or fatal injury.
Warning:
Suspended load. Warning: Dangerous electrical
voltage.

2
Ausgabe
issue D / 06.01.2014 Dokument document OM.SAF.01e Blatt sheet 2 (4)
1
Safety
1.2.3 Information symbols
¾Instruction to act/take measures
• List item
1.3 Dangers that can be caused by the machine
seepex machines are built in accordance with the state of the art.
Nevertheless, there is a residual risk, because the machine works with:
• Mechanical movements that pose a danger
• Electrical voltages and currents
We have used design measures and applied safety technology to minimise the risk to the
health of people posed by this danger.
1.4 Qualification of the personnel
This handbook is intended for:
• Owner
• Operators
•Setters
• Maintenance personnel
1.5 Authorised people
People authorised to undertake operation, set up and maintenance are instructed and trained
specialists employed by the owner/manufacturer.
The owner is responsible for:
• Personnel training
• Compliance with safety regulations
• Compliance with operating and maintenance instructions
The operator must:
• Have received instruction
• Read and understood the relevant parts of the operating instructions before starting work
• Know the safety devices and regulations
NOTICE
Ensure environmen-
tal protection. Wear eye protection.
Detailed technical knowledge is essential for performing any work on the machine.

3
Ausgabe
issue D / 06.01.2014 Dokument document OM.SAF.01e Blatt sheet 3 (4)
1
Safety
1.5.1 Tasks and information for the owner/operators
¾Regularly check and maintain the machine, replacing all parts in good time which no longer
guarantee safe operation.
¾It is essential to comply with the procedure described in the operating instructions for shut-
ting down the machine.
• On completion of work, attach all safety and protective devices and make sure they are
functioning.
1.5.2 Safety notes for maintenance, inspection and assembly work
¾Do not work on the machine or system unless it is stationary and depressurised.
¾Switch off the master switch and pull out the power plug before starting work on live com-
ponents.
¾Comply with the procedure for shutting down the machine as described in the Shut-down
chapter.
¾Decontaminate (de-toxify) machines that are used for pumping media that can be harmful
to health.
¾Refer to the Initial start-up chapter before repeated start-up of the machine.
1.6 Personal protective equipment
¾Wear personal protective equipment and/or additional equipment for your own safety.
¾Avoid/limit risks by the use of collective technical protective equipment or by organisational
measures at work.
1.7 Safety and protective devices
¾Prior to start-up, bolt seepex machines onto a concrete foundation so as to ensure stability.
¾Starting and stopping devices must be clearly recognisable. Take appropriate measures to
avoid defects.
• No protective device is necessary for checking and/or setting the shaft seal.
• Hot surfaces are identified with a danger symbol on the machine.
1.8 Foreseeable misuse
Serious personal injury and damage to property can be caused by:
• Incorrect use
• Incorrect installation or operation of the machine
• Impermissible removal of necessary protective equipment

4
Ausgabe
issue D / 06.01.2014 Dokument document OM.SAF.01e Blatt sheet 4 (4)
1
Safety
1.9 Designated use
• Only use seepex machines if they are in perfect condition and in compliance with the oper-
ating and maintenance instructions.
• Do not start up the machine unless the system in which the machine is installed is in accor-
dance with the provisions of the applicable guidelines and statutory regulations.
• Equivalent sustained sound pressure level at workplaces of operating personnel C75 dB
(A). Cavitation-free operation of the machine and screwed connection to concrete founda-
tion are essential.
• seepex machines are components that are exclusively intended for pumping media in ac-
cordance with the technical data (→chapter 3). Written approval must be obtained from the
manufacturer before other media are pumped.
• Refer to the information on the type plate and the operating instructions for technical data
(→chapter 3), and comply with them.
• The operating instructions are assigned to the seepex machine based on the commission
number.
Fig. 1-1 Similar illustration
1.10 Warranty
• Warranty in accordance with our terms and conditions of delivery and order confirmation.
• It is a condition of the machine warranty that the machine must correspond to the listed op-
erating instructions in accordance with the type plate/data sheet.
• All wearing parts are excluded from the warranty.
• Theseoperatinginstructionsaresubject to copyright.Reproductionisnot permitted and will
be punished. Contravention will be pursued through the courts.

5
Ausgabe
issue D / 29.04.09 Dokument document OM.SAF.02e Blatt sheet 1 (4)
1
Safety
1.11 Safety clearances
1.11.1General • Open hopper pumps are not ready-to-run units in delivery condition, therefore they are sup-
plied with a declaration by the manufacturer.
• The owner is responsible for appropriate protective devices/feeder hoppers in order to
guarantee conformity of the system.
1.11.2Applicability of the safety clearances
• Inadequate protection for certain dangers (e.g. radiation and substance emissions).
– Additional or other measures necessary.
• Protection for those persons who are attempting to reach danger areas without additional
help and under the conditions defined for various situations of reaching up, reaching under
or reaching through.
1.11.3Definition
1.11.3.1 Protective structure
Use a physical barrier (e.g. guard, part of a machine) in order to limit movement of the body
or a body part.
1.11.3.2 Safety clearance
Use appropriate minimum clearance by means ofprotective structure in front of the danger
area.
1.11.4Values for safety clearances
1.11.4.1 Precondition
Safety clearances defined as follows:
• Protective structures and openings in them retain their shape and position.
• Measure safety clearances between limiting surfaces and the body or affected body part.
• Danger area can be reached with difficulty.
• The reference level is the level on which people normally stand, e.g. floor or working plat-
form.
• Do not use any objects such as chairs, ladders to change the reference level.
• Do not use any objects such as rods or tools to extend the natural reach of upper extremi-
ties.
1.11.5Reaching overprotective structures
The following code letters are used
a = Height of the danger area
b = Height of the protective structure
c = Horizontal distance to the danger area
If the danger area represents a severe risk, then the values in the table or other technical
safety measures must be used.
If the known values for a, b or c fall between two values in the table, use values that result
in a higher level of safety.

6
1
Safety
Ausgabe
issue D / 29.04.09 Dokument document OM.SAF.02e Blatt sheet 2 (4)
Height of
the danger
area
a
Height of the protective structure b1)
1000 1200 14003) 1600 1800 2000 2200 2400 2600 2700
Horizontal distance to the danger area c
27002) ----------
2600 900 800 700 600 600 500 400 300 100 -
2400 1100 1000 900 800 700 600 400 300 100 -
2200 1300 1200 1000 900 800 600 400 300 - -
2000 1400 1300 1100 900 800 600 400 - - -
1800 1500 1400 1100 900 800 600 - - - -
1600 1500 1400 1100 900 800 500 - - - -
1400 1500 1400 1100 900 800 - - - - -
1200 1500 1400 1100 900 700 - - - - -
1000 1500 1400 1000 800 - - - - - -
800 1500 1300 900 600 - - - - - -
600 1400 1300 800 - - - - - - -
400 1400 1200 400 - - - - - - -
200 1200 900 - - - - - - - -
01100500--------
1) Protective structures less than 1000 mm in height are not included, because
movement is not satisfactorily restricted.
2) If the danger area represents a minor risk, the height h of the danger area must
be 2500 mm or more.
If the danger area represents a high risk, then
• either the height h of the danger area must be 2700 mm or more
• or other technical safety measures must be used..
3) Protective structures below 1400 mm should not be used without additional
technical safety measures. (Source: DIN EN ISO 13857)
G
S
B
ab
c
S
c
ab
G
G
AST
a

7
1
Safety
Ausgabe
issue D / 29.04.09 Dokument document OM.SAF.02e Blatt sheet 3 (4)
1.11.6Reaching around/reaching through openings
Danger in the working area of rotating shafts.
1.12 Guard
1.12.1Pump with feeder hopper (AST), inspection hatch (KIS) with safety switch (SHS)
Limitation of movement Safety clearance sr Figure
Only at shoulder and armpit 850
Arm supported up to the elbow 550
Arm supported up to the wrist 230
Arm and hand supported up to
the finger root 130
A: Movement area of the arm
1) Either diameter of a round opening, side of a square opening or width of a slot-
shaped opening (source: DIN EN ISO 13857)
=120
sr
A
1)
sr
=300
=1201)
A
sr
=620
=1201)
A
sr
=720
=1201)
A
Beforestart-up,integratethe safety switch
into the electric control system so that the
followingcomponentsareswitchedoffand
prevented from reactivation when inspec-
tion hatch (KIS) is opened.
– Bridge breaker driver
– Pump drive
– Other drive units projecting into the in-
terior
Switch off all media feeds in the feeder
hopper immediately.
Restartthesystem afterclosinginspection
hatch (KIS).
Press reset to switch on the components.
G
SHS AST
KIS

8
1
Safety
Ausgabe
issue D / 29.04.09 Dokument document OM.SAF.02e Blatt sheet 4 (4)
1.12.2Pump with cleaning cover
1.12.3Pump with cover
1.13 Filling level hopper (500)
Before opening cleaning cover (RGD),
switch off the pump drive and bridge
breakerdriveandpreventthemfrombeing
switched back on.
Startupthepumpdriveandbridgebreaker
drive after closing cleaning cover (RGD).
G
RGD
Open cover (DEK) for topping-up purpos-
es, but first switch off the pump drive and
secure it against being switched back on.
– The owner may install a safety switch
which is integrated in the electric con-
trol unit.
Do not switch on the drive until after clos-
ing the cover.
DEK
• Fill in the hopper (500) max. up to the top
edge of the auger feed screw.
• Install alternative a level control (F).
500
F

9
Ausgabe
issue B / 12.11.2012 Dokument document OM.DES.01e Blatt sheet 1 (1)
2
Description of the pump
2.1 General description
seepex pumps are members of the group of rotating displacement pumps.
• Characteristic features
– Special configuration/arrangement of the rotor and stator pumping elements.
– Motion sequence
2.2 Mode of action and pumping principle of the seepex pump
• Sealing bands are produced through geometric design/contact of both conveying elements.
• Sealing bands ensure a perfect fit between the suction and pressure side.
Result:
– Increased pump suction.
– Higher pressure build-up independent of speed possible.
2.3 Constructive design
No. Designation
ANT Drive
200 Lantern
307 Plug-in shaft
400 Coupling rod
SEA Shaft seal
500 Suction casing
600 Rotor
RTE Rotating unit
601 Stator
700 Pressure branch

10

11
Ausgabe
issue A / 29.06.2017 Dokument document OM.TED.XXeBlatt sheet 1 (1)
3
Technical data
3.1 Data sheet
3.2 Characteristic Curves
3.3 Declaration
•Data sheet, characteristic curves and declarations are commission specific documents
and not part of this not binding operating and assembly instruction.

12

13
Ausgabe
issue D / 27.08.2012 Dokument document OM.TRA.01e Blatt sheet 1 (2)
4
Transport, Intermediate storage, Disposal
4.1 Safety
4.2 Transport
4.2.1 Dimensions, weights and center of gravity
¾Note the dimensional drawing (→ chapter 5.6).
4.2.2 Symbols • Meaning of symbol
4.2.3 Sling points (AP) for lifting devices
4.2.4 Unpacking the machine
¾Comply with the symbols and notices on the packaging.
¾Remove the screwed connection between the machine and packaging.
¾Remove the machine with a lifting machine/industrial truck.
4.3 Temporary storage/Corrosion protection
• All seepex machines have corrosion protection applied as standard prior to transport.
CAUTION
Damage to property/injuries due to incorrect transport
Slight injury or damage to property can occur
¾Comply with the safety notes and transport notes on the packaging.
¾Use suitable means of transport, lifting devices and tools.
¾Use protective equipment.
Top Fragile
item Againstmoisture protect Centre of gravity Lashing points
WARNING
Warning of suspended load.
Death of serious injury can occur.
¾Use the lashing points (AP) for lifting divices.
¾Note the centre of gravity (→ dimensional drawing, chapter 5.6).
Lifting machine Industrial trucks

14
Ausgabe
issue D / 27.08.2012 Dokument document OM.TRA.01e Blatt sheet 2 (2)
4
Transport, Intermediate storage, Disposal
4.4 Disposal
NOTICE
Damage to property if corrosion protection is missing
Property damage can occur due to corrosion.
¾Temporary storage must be in a dry, enclosed, frost-free room in order to provide protec-
tion against ambient influences.
¾Contact seepex regarding the necessary corrosion protection for temporary storage.
NOTICE
Environmental protection
Material damage can occur.
¾Drain the pumping medium and dispose of it in accordance with the regulations.
¾Dispose of the machine with regard to its composition and existing regulations.