SPX Johnson Pump CombiPrime V User manual

Instruction Manual
CombiPrime V
Vertical self-priming centrifugal pump
Orginal instructions
Read and understand this manual prior to
operating or servicing this product.
CV/EN (1009) 5.3

EC/EN (1001) 5.1 1
EC Declaration of conformity
(Directive 2006/42/EC, appendix II-A)
Manufacturer
SPX Process Equipment NL B.V.
Dr. A.F. Philipsweg 51
9403 AD Assen
The Netherlands
hereby declares that all pumps member of productfamilies CombiBloc, CombiBlocHorti,
CombiChem, CombiDirt, CombiFlex(U)(B), CombiPrime H, CombiLine, CombiLineBloc,
CombiMag, CombiMagBloc, CombiNorm, CombiPro(M)(V), CombiPrime V, CombiSump,
CombiWell, FRE, FRES, FREF, FREM, KGE(L), KGEF, HCR, MCH(W)(S), MCHZ(W)(S),
MCV)(S), PHA, MDR whether delivered without drive (last position of serial number = B),
or delivered as an assembly with drive (last position of serial number = A), are in
conformity with the provisions of Directive 2006/42/EC (as altered most recently) and
where applicable the following directives and standards:
• EC directive 2006/95/EG, "Electric equipment for use within certain voltage limits"
• standards EN-ISO 12100 part 1 & 2, EN 809
The pumps to which this declaration refers may only be put into operation after they have
been installed in the way prescribed by the manufacturer, and, as the case may be, after
the complete system of which these pumps form part, has been made to fulfil the
requirements of Directive 2006/42/EC (as altered most recently).
Declaration of incorporation
(Directive 2006/42/EC, appendix II-B)
Manufacturer
SPX Process Equipment NL B.V.
Dr. A.F. Philipsweg 51
9403 AD Assen
The Netherlands
hereby declares that the partly completed pump (Back-Pull-Out unit), member of
productfamilies CombiBloc, CombiBlocHorti, CombiChem, CombiDirt, CombiFlex(U)(B),
CombiPrime H, CombiLine, CombiLineBloc, CombiMag, CombiMagBloc, CombiNorm,
CombiPro(M)(V), CombiPrime V, FRE, FRES, FREF, FREM, KGE(L), KGEF, HCR, PHA, MDR is
in conformity with the following standards:
• EN-ISO 12100 parts 1 & 2, EN 809
and that this partly completed pump is meant to be incorporated into the specified pump
unit and may only be put into use after the complete machine of which the pump under
consideration forms part has been made and declared to comply with that directive.
Assen, January 1st 2010
G.A. Schaafsma,
General Manager

2EC/EN (1001) 5.1

CV/EN (1009) 5.3 3
CombiPrime V
Instruction manual
CombiPrime V
All technical and technological information in this manual as well as possible drawings
made available by us remain our property and shall not be used (otherwise than for the
operation of this pump), copied, duplicated, made available to or brought to the notice of
third parties without our prior written consent.
SPX Process Equipment NL B.V. (hereafter called Johnson Pump) is part of SPX
Process Equipment AB. The core activities of SPX Process Equipment AB are the
development, production, sale and maintenance of pumps and pump units.
SPX Process Equipment NL B.V.
P.O. B ox 9
9400 AA Assen
The Netherlands
Tel. [phone]
Fax. [phone]
© 2008 SPX Process Equipment NL B.V.

4CV/EN (1009) 5.3

CV/EN (1009) 5.3 5
CombiPrime V
Table of Contents
1 Introduction 9
1.1 Preface 9
1.2 Safety 9
1.3 Guarantee 10
1.4 Inspection of delivered items 10
1.5 Instructions for transport and storage 11
1.5.1 Weight 11
1.5.2 Use of pallets 11
1.5.3 Hoisting 11
1.6 Storage 12
1.7 Ordering parts 12
2 General 13
2.1 Pump description 13
2.2 Type code 13
2.3 Serial number 14
2.4 Applications 14
2.5 Construction 14
2.5.1 Pump casing/impeller/suction bend 14
2.5.2 Shaft sealing 15
2.5.3 Self-priming part 15
2.5.4 Bearing construction 15
2.5.5 Lantern construction 15
2.5.6 Foot pads 15
2.6 Application area 15
2.7 Re-use 16
2.8 Scrapping 16
3Installation 17
3.1 Safety 17
3.2 Preservation 17
3.3 Environment 17
3.4 Mounting 18
3.4.1 Installation of a pump unit 18
3.4.2 Assembling a pump unit 18
3.4.3 Alignment of the coupling 19
3.4.4 Tolerances for aligning the coupling 19
3.5 Piping 20
3.6 Accessories 20
3.7 Vacuum pump with service liquid tank 21

6CV/EN (1009) 5.3
3.7.1 Mounting of accessories 21
3.7.2 Connection diagram with service liquid tank 21
3.7.3 Indication of connections 21
3.7.4 Installation examples with service liquid tank 22
3.8 Vacuum pump with float-controlled de-aerator 26
3.8.1 Mounting of accessories 26
3.8.2 Connection diagram with float-controlled de-aerator 26
3.8.3 Indication of connections 26
3.8.4 Installation examples with float-controlled de-aerator 27
3.9 Connection of the electric motor 30
4 Commissioning 31
4.1 Inspection of the pump 31
4.2 Inspection of the vacuum pump part 31
4.3 Inspection of the motor 31
4.4 Checking the sense of rotation 31
4.5 Start-up 31
4.6 Adjusting the air-inlet valve 32
4.7 Mechanical seal 32
4.8 Pump in operation 32
4.9 Noise 32
5 Maintenance 33
5.1 Daily maintenance 33
5.2 Service liquid 33
5.3 Shaft sealing 33
5.3.1 Mechanical seal 33
5.3.2 Lip seal 33
5.4 Lubrication of the bearings 33
5.5 Environmental influences 34
5.6 Noise 34
5.7 Faults 34
6 Problem solving 35
7 Disassembly and assembly 37
7.1 Precautionary measures 37
7.2 Special tools 37
7.3 Liquid draining 37
7.4 Item numbers 37
7.5 Constructive variants 38
7.6 Top Pull Out system 38
7.6.1 Disassembly Top Pull Out unit 38
7.6.2 Assembly Top Pull Out unit 38
7.7 Replacing the impeller and the wear ring 39
7.7.1 Disassembly of the impeller 39
7.7.2 Mounting the impeller 39
7.7.3 Disassembling of the wear ring 40
7.7.4 Assembling the wear ring 40
7.8 Shaft sealing 41
7.8.1 Disassembly of the mechanical seal M2 41
7.8.2 Instructions for mounting a mechanical seal 42
7.8.3 Assembly of the mechanical seals M2 42
7.8.4 Disassembly of the lip seals M4 43
7.8.5 Instructions for mounting a lip seal 44
7.8.6 Assembly of the lip seals M4 44

CV/EN (1009) 5.3 7
CombiPrime V
7.9 Bearing 45
7.9.1 Disassembling bearing 45
7.9.2 Assembling bearing 46
7.10 Adjustment of the axial play 47
8Dimensions 49
8.1 Dimensions delivery flange 49
8.2 Dimensions suction flange 50
8.3 Dimensions foot pads 51
8.4 Dimensions foot pads 200-200 / 250B-315 51
8.5 Pump dimensions 52
8.6 Pump dimensions with suction bend 54
8.7 Pump dimensions 200-200 / 250B-315 with suction bend 56
8.8 Pump dimensions with service liquid tank 58
8.9 Pump dimensions with float de-aerator 60
9Parts 63
9.1 Ordering parts 63
9.1.1 Order form 63
9.1.2 Recommended spare parts 63
9.2 Pump 64
9.2.1 Sectional drawing 64
9.2.2 Parts list 65
9.3 Shaft sealing group M2 67
9.3.1 Mechanical seal MG1-G60 67
9.3.2 Parts list mechanical seal MG1-G60 67
9.4 Shaft sealing group M4 68
9.4.1 Lip seal 68
9.4.2 Parts list lip seal 68
9.5 Service liquid tank TL 69
9.5.1 Service liquid tank TL 69
9.5.2 Parts of service liquid tank TL 70
9.6 Float de-aerator VL 71
9.6.1 Float de-aerator VL 71
9.6.2 Parts of float de-aerator VL 72
9.7 Suction bend 73
9.7.1 Sectional drawing suction bend 73
9.7.2 Parts of suction bend 73
9.7.3 Sectional drawing suction bend 200-200 / 250B-315 74
9.7.4 Parts of suction bend 200-200 / 250B-315 74
10 Technical data 75
10.1 Recommended greases 75
10.2 Recommended locking liquids 75
10.3 Tightening moments 75
10.3.1 Tightening moments for bolts and nuts 75
10.3.2 Tightening moments for cap nut 75
10.4 Hydraulic performance 76
10.5 Noise data 78
10.5.1 Pump noise as a function of pump power 78
10.5.2 Noise level of entire pump unit 79
Index 81
Order form for spare parts 83

8CV/EN (1009) 5.3

CV/EN (1009) 5.3 Introduction 9
CombiPrime V
1 Introduction
1.1 Preface
This manual is intended for technicians and maintenance staff and for those who are in
charge of ordering spare parts.
This manual contains important and useful information for the proper operation and
maintenance of this pump. It also contains important instructions to prevent potential
accidents and damage, and to ensure safe and fault-free operation of this pump.
! Read this manual carefully before commissioning the pump, familiarize
yourself with the operation of the pump and strictly obey the instructions!
The data published here comply with the most recent information at the time of going to
press. However they may be subject to later modifications.
Johnson Pump reserves the right to change the construction and design of the products
at any time without being obliged to change earlier deliveries accordingly.
1.2 Safety
This manual contains instructions for working safely with the pump. Operators and
maintenance staff must be familiar with these instructions.
Below is a list of the symbols used for those instructions and their meaning:
Personal danger for the user. Strict and prompt observance of the
corresponding instruction is imperative!
! Risk of damage or poor operation of the pump. Follow the corresponding
instruction to avoid this risk.
➢Useful instruction or tip for the user.
Items which require extra attention are shown in bold print.
This manual has been compiled by Johnson Pump with the utmost care. Nevertheless
Johnson Pump cannot guarantee the completeness of this information and therefore
assumes no liability for possible deficiencies in this manual. The buyer/user shall at all
times be responsible for testing the information and for taking any additional and/or
deviating safety measures. Johnson Pump reserves the right to change safety
instructions.

10 Introduction CV/EN (1009) 5.3
1.3 Guarantee
Johnson Pump shall not be bound to any guarantee other than the guarantee accepted
by Johnson Pump. In particular, Johnson Pump will not assume any liability for explicit
and/or implicit guarantees such as but not limited to the marketability and/or suitability of
the products supplied.
The guarantee will be cancelled immediately and legally if:
• Service and/or maintenance is not undertaken in strict accordance with the
instructions.
• The pump is not installed and operated in accordance with the instructions.
• Necessary repairs are not undertaken by our personnel or are undertaken without our
prior written permission.
• Modifications are made to the products supplied without our prior written permission.
• The spare parts used are not original Johnson Pump parts.
• Additives or lubricants used are other than those prescribed.
• The products supplied are not used in accordance with their nature and/or purpose.
• The products supplied have been used amateurishly, carelessly, improperly and/or
negligently.
• The products supplied become defective due to external circumstances beyond our
control.
All parts which are liable to wear are excluded from guarantee. Furthermore, all
deliveries are subject to our “General conditions of delivery and payment”, which will be
forwarded to you free of charge on request.
1.4 Inspection of delivered items
Check the consignment immediately on arrival for damage and conformity with the advice
note. In case of damage and/or missing parts, have a report drawn up by the carrier at
once.

CV/EN (1009) 5.3 Introduction 11
CombiPrime V
1.5 Instructions for transport and storage
1.5.1 Weight
A pump or a pump unit is generally too heavy to be moved by hand. Therefore, use the
correct transport and lifting equipment. Weight of the pump or pump unit are shown on
the label on the cover of this manual.
1.5.2 Use of pallets
Usually a pump or pump unit is shipped on a pallet. Leave it on the pallet as long as
possible to avoid damages and to facilitate possible internal transport.
! When using a forklift always set the forks as far apart as possible and lift the
package with both forks to prevent it from toppling over! Avoid jolting the
pump when moving it!
1.5.3 Hoisting
When hoisting a pump or complete pump units the straps must be fixed in accordance
with figure 1.
When lifting a pump or a complete pump unit always use a proper and sound
lifting device, approved to bear the total weight of the load!
Never go underneath a load that is being lifted!
! If the electric motor is provided with a lifting eye, this lifting eye is intended
only for the purpose of carrying out service activities to the electric motor!
The lifting eye is designed to bear the weight of the electric motor only!
It is NOT permitted to lift a complete pump unit at the lifting eye of an electric
motor!
Figure 1: Lifting instructions for pump unit.

12 Introduction CV/EN (1009) 5.3
1.6 Storage
If the pump is not to be used immediately the pump shaft must be turned by hand twice
per week.
1.7 Ordering parts
This manual contains a survey of the spare parts recommended by Johnson Pump as well
as the instructions for ordering them. A fax-order form is included in this manual.
You should always state all data stamped on the type plate when ordering parts and in
any other correspondence regarding the pump.
➢This data is also printed on the label on the front of this manual.
If you have any questions or require further information with regard to specific subjects,
then do not hesitate to contact Johnson Pump.

CV/EN (1009) 5.3 General 13
CombiPrime V
2 General
2.1 Pump description
The CombiPrime V is a range of vertical self-priming centrifugal pumps. Hydraulic
application area complies with EN 733 (DIN 24255) (with the exception of 250B-315).
The flange dimensions, bolt circle and number of holes comply with ISO 7005 ND 10.
The CombiPrime V is characterized by the built-in vacuum pump. Thus it is possible to
pump fluids mixed with air (gas) or only air during the suction phase. The built-in vacuum
pump is based on the liquid ring principle. The pump is driven by a standard IEC flange
motor. The power is transmitted through a flexible coupling. Because of their modular lay-
out, constructional components are widely interchangeable, also with other pump types
of the Combi system.
2.2 Type code
Pumps are available in various designs. The main characteristics of the pump are shown
in the type code.
Example: CV 40-200 B2 M2 TL
Pump family
CV CombiPrime V
Pump size
40-200 diameter discharge connection [mm] - nominal impeller diameter [mm]
Pump casing/pump cover and impeller material
G1 pump casing/pump cover: cast iron impeller: cast iron
G2 pump casing/pump cover: cast iron impeller: bronze
G3 pump casing/pump cover: cast iron impeller: aluminium bronze
B2 pump casing/pump cover: bronze impeller: bronze
B3 pump casing/pump cover: bronze impeller: aluminium bronze
Shaft sealing
M2 mechanical seal on shaft sleeve
M4 lip seals on shaft sleeve
De-aerating unit
TL service liquid tank + air inlet valve
VL float de-aerator + air inlet valve

14 General CV/EN (1009) 5.3
2.3 Serial number
Serial number of the pump or pump unit are shown on the name plate off the pump and
on the label on the cover of this manual.
2.4 Applications
• In general, this pump can be used for thin, clean or slightly polluted liquids. These
liquids should not affect the pump materials.
• The maximum allowed system pressure and temperature and the maximum speed
depend on the pump type and the pump construction. For relevant data see paragraph
2.6 "Application area".
• Further details about the application possibilities of your specific pump are mentioned
in the order confirmation and/or in the data sheet enclosed with the delivery.
• Do not use the pump for purposes other than those for which it is delivered without
prior consultation with your supplier.
Using a pump in a system or under system conditions (liquid, working
pressure, temperature, etc.) for which it has not been designed may hazard
the user!
2.5 Construction
The pump has a modular design. The main components are:
• Pump casing/impeller/suction bend
• Shaft sealing
• Self-priming unit
•Bearing
• Lantern construction
• Foot pads
The pumps are available in 3 bearing groups, meaning that bearing and shaft sealing are
divided into 3 groups. Furthermore, the pumps have been standardized in 5 groups
featuring the same connection for pump cover and bearing pedestal, depending on the
nominal impeller diameters. The pump covers are clamped between the pump casing
and bearing bracket.
2.5.1 Pump casing/impeller/suction bend
These are the parts that get into contact with the pumped liquid. For each individual
pump type there is only one construction of the pump casing and the impeller. The pump
casing and the suction bend are available in cast iron and in bronze, the impeller in cast
iron, bronze and aluminium bronze. The pump shaft is available in alloyed and stainless
steel. With the available materials the pumps can be supplied in a construction suitable
to pump sea water. The square suction bend has been designed in such a way that
resistance is low an that all the same a low position of the pump in relation to the floor is
possible. The pump types 200-200, 250B-315 have a fabricated suction bend. The
suction bend can be mounted in different positions in relation to the discharge flange.
This offers a large number of mounting possibilities.
Example: 01-1000675A
01 year of manufacture
100067 unique number
5number of pumps
Apumpwithmotor
Bpump with free shaft end

CV/EN (1009) 5.3 General 15
CombiPrime V
2.5.2 Shaft sealing
On both sides of the self-priming part there is a mechanical seal or a number of lip seals.
Both are mounted on shaft sleeves, which have been sealed in such a way that the
pumped liquid cannot touch the pump shaft. The mechanical seals meet EN 12756 (DIN
24960), with the exception of the mounting length. The lip seals are mounted on
stainless steel shaft sleeves which have been provided with a hard chromium oxide
wearing layer.
2.5.3 Self-priming part
The self-priming part consists of a built-in vacuum pump which is working according to
the liquid ring principle, an air-inlet valve with a check valve and a service liquid tank or
float controlled air-relief valve. The vacuum pump part is mounted on the pump shaft, but
works separately from the centrifugal pump. The service liquid which is supplied to the
hub section of the vacuum pump has to maintain the liquid ring. Apart from that, it also
serves for cooling and lubrication of the vacuum pump and the shaft seals.
2.5.4 Bearing construction
The bearing construction consists of 2 angular contact ball bearings combined with a
cylindrical bearing. The bearings are grease lubricated. The angular contact bearings are
mounted in a adjusting sleeve, with which the entire pump shaft can be shifted in order to
adjust the axial tolerance of the pump wheel.
2.5.5 Lantern construction
The construction that supports the motor (the lantern) consists of profiled steel elements.
The openings between these elements are sealed with perforated steel plate. Pump and
motor are coupled by means of a flexible coupling with spacer sleeve ('spacer'). After the
guards and spacer have been removed, the rotating part of the pump can be easily
dismantled as a whole without having to disconnect the electric motor or the piping. This
construction is called the Top Pull Out principle.
2.5.6 Foot pads
If the pump has been constructed with foot pads, the pads have to be fastened to the
foundation. The 200-200, 250B-315 are supplied with a feet support made of welded
pipe and flanges. It is also possible to construct the pump without foot pads and suction
bend. In that case, the pump casing is mounted on the foundation and immediately
provided with a vertical suction pipe.
2.6 Application area
The application area globally looks as follows:
However, the maximum allowable pressures and temperatures depend strongly on the
selected materials and components. Also working conditions may cause differences.
Table 1: Application area.
Maximum value
Capacity 800 m3/h
Discharge head 100 m
System pressure 10 bar
Temperature 80°C

16 General CV/EN (1009) 5.3
2.7 Re-use
The pump may only be used for other applications after prior consultation with Johnson
Pump or your supplier. Since the lastly pumped medium is not always known, the
following instructions should be observed:
• Flush the pump properly.
• Make sure the flushing liquid is discharged safely (environment!)
Take adequate precautions and use the appropriate personal protection
means (rubber gloves, spectacles)!
2.8 Scrapping
If it has been decided to scrap a pump, the same flushing procedure as described for
Re-use should be followed.

CV/EN (1009) 5.3 Installation 17
CombiPrime V
3Installation
3.1 Safety
• Read this manual carefully prior to installation and commissioning. Non-observance of
these instructions can result in serious damage to the pump and this will not be
covered under the terms of our guarantee. Follow the instructions given step by step.
• Ensure that the pump can not be started if work has to be undertaken to the pump
during installation and the rotating parts are insufficiently guarded.
• Depending on the design the pumps are suitable for liquids with a temperature of up
to 80°C. When installing the pump unit to work at 70°C and above the user should
ensure that appropriate protection measures and warnings are fitted to prevent
contact with the hot pump parts.
• If there is danger of static electricity, the entire pump unit must be earthed.
• If the pumped liquid is harmful to men or the environment, take appropriate measures
to drain the pump safely. Possible leakage liquid from the shaft seal should also be
discharged safely.
3.2 Preservation
In order to prevent corrosion, the inside of the pump is treated with a preserving agent
before leaving the factory.
Before commissioning the pump remove any preserving agents and flush the pump
thoroughly with hot water.
3.3 Environment
• The foundation must be hard, level and flat.
• The area in which the pump is installed must be sufficiently ventilated. An ambient
temperature or air humidity which is too high, or a dusty environment, can have a
detrimental effect on the operation of the electric motor.
• There should be sufficient space around the pump unit to operate and if necessary
repair it.
• Above the cooling air inlet of the motor there must be a free area of at least ¼ of the
electric motor diameter, to ensure unobstructed air supply.

18 Installation CV/EN (1009) 5.3
3.4 Mounting
3.4.1 Installation of a pump unit
Pump and motor shafts of complete pump units are adjusted perfectly in line in the
works.
1 In case of permanent arrangement place the base plate level on the foundation with
the aid of shims.
2 Carefully tighten the nuts on the foundation bolts.
3 Check the alignment of pump and motor shafts and if necessary realign, see
paragraph 3.4.3 "Alignment of the coupling".
3.4.2 Assembling a pump unit
If the pump and the electric motor still have to assembled, do the following:
1 Remove the front guards (0270). Check if there is a key in both shaft ends.
2 Clean the motor and pump shaft. Grease both shaft ends with mounting grease.
3 Mount the flattened coupling part on the pump shaft (2200). Keep the coupling part
in line with the pump shaft end and fasten the coupling with the locking screw.
4 Fix the other coupling half on the motor shaft.
5 Place the electric motor on the flange (0260). Secure the electric motor with bolts
(0850) and nuts (0851). Push the coupling half on the motor shaft upward.
➢Wherever possible use a hoisting machine and the crane hooks on the electric motor.
6 Mount the distance sleeve on the lower coupling half.
7 Push the upper coupling half downward. For the correct distance between the
coupling halves, see figure 2 with the corresponding table. Then secure the coupling
half on the motor shaft.
8 Check whether the coupling can be turned by hand. Check the alignment, see
paragraph 3.4.3 "Alignment of the coupling".
9 Mount the guards.

CV/EN (1009) 5.3 Installation 19
CombiPrime V
3.4.3 Alignment of the coupling
1 Use bolts (0890) to position the electric motor in such a way that the coupling halves
are aligned correctly.
2 Place a ruler against the coupling. The ruler should touch both coupling halves over
the entire length, see figure 2A.
3 Do this check a couple of times around the entire coupling.
3.4.4 Tolerances for aligning the coupling
The maximum allowable tolerances for the alignment of the coupling halves are shown in
Table 2. See also figure 2B.
Figure 2: Alignment of the coupling.
Tabel 2: Alignment tolerances
External diameter
of coupling [mm]
Va Vrmax [mm]
min [mm] max [mm]
81-95 5 6 0,15
96-110 5 6 0,18
111-130 5 6 0,21
131-140 5 6 0,24
141-160 6 7 0,27
161-180 6 7 0,30
181-200 6 7 0,34
201-225 6 7 0,38
225-250 7 9 0,42
251-280 7 9 0,47
Vr
Va
AB