Sulzer AHLSTAR 2.15 Series Manual

COPYRIGHT © SULZER PUMPS FINLAND OY
ORIGINAL INSTRUCTION
SERIES 2.15
SPP id: 150201 / Replaces 141101 / en / N32197 / 5
AHLSTAR
PROCESS PUMPS
Installation, operation and maintenance instruction
Intended use
Safety instructions
Hoisting and transportation
Commissioning
Installation at the site
Operation
Preventive maintenance
Corrective maintenance
Spare parts recommendation

USER'S MANUAL – AHLSTAR
Documents & Dates
SPP id: 150201 / Replaces 141101 / en / N32197 / 5 / Page 2 (2)
Series 2.15
INSTRUCTIONS
February 2015
Page
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COPYRIGHT © SULZER PUMPS FINLAND OY
ORIGINAL INSTRUCTION
Installation, operation and maintenance instruction
G ISO
N32197 Cover Feb - 15
G ISO Table of contents
G ISO N31567 Intended use Nov - 14
G ISO N31568 Safety instructions Feb - 15
G N31569 Hoisting and transportation Jun - 12
G N31570 Commissioning Sep - 11
G ISO N31571 Installation at the site Nov - 13
G ISO N31572 Operation Jun - 12
G ISO N31573 Preventive maintenance Nov - 14
G ISO N32198 Corrective maintenance Sep - 14
G ISO N31575 Spare parts recommendation Sep - 11

COPYRIGHT © SULZER PUMPS FINLAND OY
ORIGINAL INSTRUCTION
SERIES 2.15
SPP id: 141101 / Replaces 140901 / en / N31567 / 4
AHLSTAR
PROCESS PUMPS
Intended use
1General
2Document identification
3Type designation
4Parts number designation
5Nameplate designation
6Capacity and head
7Decommissioning

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COPYRIGHT © SULZER PUMPS FINLAND OY
ORIGINAL INSTRUCTION
USER'S MANUAL – AHLSTAR
Intended use
1 General
W A R N I N G
The pump and its accessories may only be used for the purpose for which they have been supplied.
The intended use is given in the order specification and in the following instructions concerning the main pumping
parameters and mechanical durability. If the intended use changes, the user must make sure that the pump can be
used in the new application and, if necessary, obtain the manufacturer’s permission for the change.
C A U T I O N
The maximum allowable working pressure of the pump is indicated in the product specification (under
item pump). Please note this also when using a frequency converter.
Table 1, Intended use in the process
Application data: Sources:
Pumped liquid and its properties (chemicals, solids,
consistency, temperature etc.)
Product specification (under “Process data”)
Main pumping parameters (capacity, head, speed etc.) Product specification (under “Process data”) and nameplate of
the pump
Other necessary process data Product specification (under “Process data”)
Table 2, Delivery and design
Delivery and design data: Sources:
Product scopes (modules) Product specification
Product size Product specification and nameplate of the pump
Other design alternatives (impeller type and size, materials,
lubrication, flange drillings, shaft sealing type etc.)
Product specification
Maximum allowable working pressure Product specification
Dimensions (pump, accessories, flanges etc.) Dimensional drawings
Weights and mass moments of inertia (bare pump, pump +
baseplate etc.)
Dimensional drawings
Connections (lubrication, shaft seal, drainage etc.) Location shown in the parts list and in the sectional drawings
and dimensional drawings. Moreover, connections having
importance in view of safety have been marked on the
product.
Part details (maximum impeller diameter, bearing types,
fastener sizes etc.)
Parts list (under heading “Parts”)
This instruction set covers the process pump with the supplementary accessories included in the delivery. All
supplied instructions are found in the parts list under the heading ”Customer instructions”.
Before commissioning, the operating staffs have to be instructed in the guidelines for correct and safe operation of
the product as stated in these instructions. This product must be serviced by qualified personnel who are familiar
with the design and operation of this product and the system with the essential safety aspects involved. The scope of
responsibilities and supervision of the personnel must be exactly defined by the plant operator.

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COPYRIGHT © SULZER PUMPS FINLAND OY
ORIGINAL INSTRUCTION
USER'S MANUAL – AHLSTAR
Intended use
Our guarantee will be valid only if the installation, operation, maintenance and repairs of this pump are carried out in
accordance with these instructions. The plant operator is to make sure that the contents of these instructions are
fully understood by the operating personnel.
To assure a steady start-up, supervision or service from an authorized manufacturer representative is
recommended. During operation, periodic inspections should be made to assure safe operation under the prevailing
conditions.
Any modification may be made to the product only after consultation with the manufacturer. Using spare parts and
accessories authorized by the manufacturer is a relevant safety aspect. Only genuine spare parts which are in
accordance with the original delivery (in the parts list) are to be used. Use of other parts may exempt Sulzer from
any liability.
If any assistance regarding the product or its instructions is required, please contact our local representative for a
quick supply of the information you need.
The enclosed instructions regarding a possible long-term storage (more than 3 months) must be observed.
All customer instructions regarding this product and its main components are also available in an electronic format
for viewing and printing (depending on the end user’s software & hardware). If electronic format is needed, please
contact our local representative for further information.
If the delivery includes customer instructions or other information in an electronic format which can be
edited, we are only responsible for the contents of paper versions of these instructions and other
information supplied by us.
Keep these instructions at the place of operation for further reference!
2 Document identification
Sulzer product number
Series 2.15 Page
INSTRUCTIONS
Identification of Sulzer document
September 2011
G
SPP id: Version 11 > / 110901 / Replaces 050101 / en / N15652 / 1 / Page 1 (2)
Page number when the document has more than one
page (total number of pages)
Document version number
Document identification number
Language of the document
The date when this document was done previously (when needed)
The date when this document was done or updated
Product version number
Sulzer Pumps Finland Oy identification

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ORIGINAL INSTRUCTION
USER'S MANUAL – AHLSTAR
Intended use
3 Type designation
A
A P P
4 3 - 250 - LM
LM = LM design liquid ring pump / mechanical seal
GM = GM design gas separator / mechanical seal
GS = GS design gas separator / static seal
S = S design liquid ring pump / mechanical seal
R = R design air separating pump / mechanical seal
Nominal diameter of discharge (mm) = 250 mm
Except the markings:
8S nominal diameter of discharge = 80 mm
10S nominal diameter of discharge = 100 mm
10P nominal diameter of discharge = 100 mm
Sealing unit size = 43
Shaft size = 4
Hydraulic construction
A = Standard process pump (mm-dimensioned structure)
APP = Standard process pump (mm-dimensioned structure)
EPP = Hot liquid pump (mm-dimensioned structure)
NPP = Non-clogging pump (mm-dimensioned structure)
WPP = Wear resistant pump (mm-dimensioned structure)
4 Parts number designation
4.1 Part numbers of modules
The delivery may include the entire pump product (PUPR.0) and/or pump spare parts. The installation-ready pump
unit is divided into the following modules: pump (PUMP.0), assembly (ASSE.0), drive unit (DRUN.0), measuring
instrumentation (MEIN.0), external degassing system (DESY.0) and documents (DOCU.0).
The pump (PUMP.0) is divided into the following modules: wet end (WEEN.1), sealing unit (SEUN.2) and bearing
unit (BEUN.3). The assembly is divided into the following modules: sealing water equipment (SWEQ.4), coupling unit
(COUN.5) and baseplate (BAPL.6). The drive unit (DRUN.0) is divided into two parts: motor (DRMO) and frequency
converter (FRCO). Documents are divided into two categories: documents supplied with the delivery and documents
supplied separately.
4.2 Part numbers of parts, connections and documents
Parts, which have part numbers consisting of a three/four-digit number plus two digits after a dot. The first digit after
the dot shows the number of the delivery unit or module in question, while the second digit distinguishes parts of the
same type from each other.
In the part number, the first digit after the dot is determined by the module. For instance, o-ring 412.11. If the module
has many parts with the same name, the second digit after the dot distinguishes the parts from each other. For
instance, 412.12 is the second o-ring in the wet end (WEEN.1).
Connections, which have part numbers consisting of the initial letter C, a two-digit number plus two digits after a dot.
The first digit after the dot shows the number of the delivery unit or module in question, while the second digit
distinguishes connections of the same type from each other.
Documents, which have part numbers consisting of the initial letter D, a two-digit number plus two digits after a dot.
The first digit after the dot shows the number of the delivery unit or module in question, while the second digit
distinguishes documents of the same type from each other.

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COPYRIGHT © SULZER PUMPS FINLAND OY
ORIGINAL INSTRUCTION
USER'S MANUAL – AHLSTAR
Intended use
5 Nameplate designation
The following nameplates have been attached to the volute casing (102.11) of each pump:
Nameplate (971.01), showing the pump’s identification data and flow properties. Fig. 1.
Caution sticker (975.01) of maximum allowable working pressure of the pump. Fig. 2.
Patent nameplate, showing the patents protecting the product. Fig. 3.
ATEX nameplate (982.01), if the product is designed for use in potentially explosive environments. Fig. 4 and
Fig. 5.
Marking:
1 Pump type 5 Speed of rotation (rpm)
2 Serial No. = Job No. 6 Space for customer Pos. No.
3 Head (m) 7 Year of manufacture
4 Capacity flow (l/s)
Fig. 1
Fig. 2
MADE UNDER ONE OR MORE OF
THE FOLLOWING US PATENTS:
NOS. 4,863,353
4,594,052
OTHER PATENTS PENDING
Fig. 3
0123 II 2 G c T3
c = The protection class used is constructional safety
T3 = Temperature class, indicates the maximum surface temperature
(200ºC)
Ex = Explosion protection marking
II = Equipment group
2 = Equipment category
G = The equipment is used in explosive atmospheres caused by gases, vapours or mists
CE marking and the mark of the notified body.
0123 = TÜV Product service, München
Fig. 4
4-942543-06
ATTENTION!
Always check the maximum
allowable working pressure
(MAWP) of this product from
the product specification.
1
2
6
3
4
5
7

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COPYRIGHT © SULZER PUMPS FINLAND OY
ORIGINAL INSTRUCTION
USER'S MANUAL – AHLSTAR
Intended use
II 3 G c T3
c = The protection class used is constructional safety
T3 = Temperature class, indicates the maximum surface temperature (200ºC)
Ex = Explosion protection marking
II = Equipment group
3 = Equipment category
G = The equipment is used in explosive atmospheres caused by gases, vapours or mists
Fig. 5
6 Capacity and head
The pump is always dimensioned according to the pumping values (flow, head) stated in the nameplate (971.01) of
the pump. Flow and head values that can be reached with the specific impeller diameter and operating speed are
given in the characteristic curve of the pump. The operating point on the curve can be changed by adjusting the
pumping system resistance e.g. by throttling the flow with the valve in the discharge piping. If the impeller diameter
or the rotational speed of the pump is changed, then the operating point will move totally to another head-flow curve.
The pump must not be used at other operating points without the following verifications:
When the pump was selected in the original operating point, all factors affecting the mechanical durability
(e.g pressure and temperature limits) and pump design (pump, impeller type, shaft sealing and lubrication
etc.) were carefully considered. All these factors are to be checked also in the new operating point.
The pump could temporarily operate even with the discharge valve closed. For continuous operation, a
minimum flow is still required. The required suction head (NPSH required) curve presented in the
characteristic curve always starts from the point of the minimum continuous flow allowed.
The suction properties of the system (NPSH available) and drive motor power are always to be checked in a
new operating point.
The efficiency of a pump is a relevant factor when estimating the lifetime costs of the pump. Therefore its
influence on the power need must be checked.
The characteristic curve enclosed is always based on tests with clean water. Other types of pumped liquid
can change the head, flow or power need values radically. These factors were recognized when the pump
was originally selected and they must be considered also in the new operating point.
7 Decommissioning
Sulzer Pumps’ products are designed so that their service would be as easy as possible by replacing worn or
damaged parts with new, original Sulzer spare parts. Parts can also be re-used after reconditioning them at Sulzer
Customer Support Service Centers. Sulzer Customer Support Service Centers must be used in the assessment of
re-use and reconditioning. If you need additional instructions or guidance, please contact our representative.
The materials used in Sulzer Pumps’ products are disclosed in the parts list supplied with the product.
At the end of the life cycle of a product or its parts, the appropriate materials and parts must be recycled or disposed
of using methods which are acceptable in terms of environmental protection and which conform to local legislation
and regulations. If a product or its part contains environmentally harmful substances, they must be removed and
disposed of by following valid regulations.

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USER'S MANUAL – AHLSTAR
Intended use
Packaging materials must be recycled or disposed of using methods which are acceptable in terms of environmental
protection and which conform to local legislation and regulations.
Make sure that hazardous substances are disposed of safely and that the personnel use appropriate personal
protective equipment. Safety considerations must always meet the requirements of valid regulations.

COPYRIGHT © SULZER PUMPS FINLAND OY
ORIGINAL INSTRUCTION
SERIES 2.15
SPP id: Version 14 > / 150201 / Replaces 140901 / en / N31568 / 8
AHLSTAR
PROCESS PUMPS
Safety instructions
1General
2Safety of machinery
3Definitions
4Essential safety aspects
5Ignition hazard assessment
6Safety signs affixed to the product
7Operating situations affecting product safety
8Balance and vibration
9Wet end
MAX
5 mm
0.2 in

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COPYRIGHT © SULZER PUMPS FINLAND OY
ORIGINAL INSTRUCTION
USER'S MANUAL – AHLSTAR
Safety instructions
1 General
This product is designed and tested for safe and reliable operation in the application for which it is specified and
sold. Remember, a pump is a piece of equipment with pressure containing parts and rotating elements which can
cause a hazard. Therefore, all the safety measures in the instructions are to be followed strictly. Personal injuries
may result if the instructions are not observed and followed.
It is not only the general safety instructions contained under this main heading ”Safety instructions” which are to be
observed, but also the specific safety information presented in other instructions relating to this delivery, relevant
national safety regulations or any other safety information issued by the plant operator.
The exact and detailed process and application data is relevant for the safe and reliable operation of the product.
Special environmental conditions at the place of installation should always be checked between the end user and
manufacturer. Such conditions are e.g.
Abnormal temperature
High humidity
Corrosive atmospheres
Pressure fluctuations
Falling below the minimum permissible flow, dry running
Explosive and/or fire risk zones
Dust, sandstorms
Earthquakes
Special safety measures are also needed when the type of liquid to be pumped is e.g. the following:
Flammable
Corrosive, abrasive
Poisonous
Crystallizing
Solid containing
Gas containing
Non-compliance with the safety and specific operating instructions may produce a risk to the personnel as well as to
the environment, e.g.
Failure of important functions of the pump and/or plant
Failure of specific procedures of maintenance and repair
Exposure of people to electrical, mechanical and chemical hazards
Endangering the environment owing to hazardous substances being released

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Safety instructions
2 Safety of machinery
2.1 General
Our delivery does not include the design of the operating environment of the machine, nor the power circuits, control
circuits and controls for the machine required in the operation of the machine. However, the European Machinery
Directive 2006/42/EC on safety of machines and/or corresponding national legislation of the country where the
machine is used are mandatory in terms of essential health and safety requirements related to the operation of the
process.
We require that the Customer has taken into account the essential requirements laid down in this instruction when
designing, purchasing and starting up the process control systems, other controls and equipment related to the
machine. Some of these requirements also concern the personnel in charge of the operation of the machine.
As far as the above is applicable, the Customer must also ensure that the valid legislation on electrical safety (such
as low-voltage directive) or electromagnetic compatibility of equipment (EMC directive) is followed.
During the operation of the machine, valid occupational safety legislation of the country where the machine is used
must also be followed.
2.2 Essential health and safety requirements
2.2.1 General remarks
2.2.1.1 Definitions
When necessary, the potential danger zones related to the machine and its operating environment, persons exposed
within the danger zone and all operator groups of the machine must be specified jointly between the Customer and
the Manufacturer, for example for the purpose of introductory training arranged for the operators of the machine.
2.2.1.2 Principles of safety integration
As a machine manufacturer, we have, in accordance with the contents of the delivery, followed the Machinery
Directive and/or the national legislation of the country where the machine is used in order to ensure safety
integration.
The installation, operating and safety instructions supplied with the machine must be followed on receipt of the
machine, in installing it at the point of operation and in its operation. Prior to final start-up, it must be ensured that the
machine, its controls and other equipment related to a safe use of the machine fulfill the requirements laid down in
the Machinery Directive and/or in national safety legislation.
2.2.1.3 Materials and products
The products related to the use of the machine (liquids transferred in the process) must not endanger the exposed
persons' safety or health. The process where the machine is used must be designed so that the use of liquids
causes no hazard.
2.2.1.4 Lighting
Maintenance areas necessary for the regular inspections of the machine must be provided with appropriate lighting.
2.2.1.5 Design of machinery to facilitate its handling
The environment of the machine must be designed so that, in order to facilitate the handling of the machine or its
various components, standard lifting gear can be attached above the machine if necessary. The environment must
be designed so that the various components can be handled safely in other respects as well. The handling and lifting
instructions supplied with the machine must be absolutely followed.

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Safety instructions
2.2.2 Controls
2.2.2.1 Control and stopping devices
The controls of the machine must be safe and constructed in a way that will prevent a dangerous situation arising.
When designing the controls, the specified requirements laid down in the Machinery Directive and/or in the national
legislation of the country where the machine is used must be absolutely followed in terms of controls, starting
devices, stopping devices (including emergency stop devices) and selection of control and operating modes for the
machine and combinations of machinery.
The controls of the machinery must be designed so that fluctuations in energy supply or failures in the control circuit
do not lead to dangerous situations. The interactive software used in the controls between the operator and the
machine must be user-friendly.
2.2.3 Protection against mechanical hazards
2.2.3.1 Stability
Our delivery includes the appropriate accessories for securing the machine to the foundations. The installation
instructions supplied with the machine must be absolutely followed in order to ensure sufficient stability of the
machine/combination of machinery.
2.2.3.2 Risk of break-up during operation
The piping and hoses connected to the machine must be able to withstand the anticipated internal and external
stresses, and they must be firmly secured and protected against all loading and stress.
The instructions concerning the purpose of the machine, limitations of use, allowable flange forces and support of
piping, supplied with the machine, must be absolutely followed. During operation, there is always a risk of rupture in
the piping connected to the machine (risk of high-pressure/hot/harmful liquid spray) if the supplied instructions are
violated.
2.2.3.3 Risk due to falling or ejected objects
Necessary precautions must be taken to prevent risks from falling or ejected objects (e.g. tools used during
installation).
2.2.3.4 Risks due to sharp edges or angles
Due to the purpose and design of the machine, its parts have sharp edges and/or angles. During installation and
maintenance, the instructions supplied with the machine must be followed, and the appropriate personal protective
equipment must be used.
2.2.3.5 Risks related to variations in the rotational speed
The instructions supplied with the machine show the intended rotational speed of the machine and its maximum
rotational speed limits. The selection and adjustment of rotational speed must be performed so that these
instructions are adhered to.
2.2.3.6 Prevention of risks related to moving parts
The fixed guards used for preventing risks related to moving parts in the machine must be absolutely kept in place
while the machine is running. If a guard is not included in the delivery, it must be ensured prior to start-up that the
rotating parts are provided with guards in accordance with the valid legislation. If rotating parts of the machine seize
accidentally during operation, the machine must be stopped immediately and the cause of the fault must be
ascertained in accordance with the instructions supplied with the machine.

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Safety instructions
2.2.4 Protection against other hazards
2.2.4.1 Electricity supply
The electrical drives of the machine must be designed, constructed and equipped so that all hazards of an electrical
nature can be prevented. The specific rules and valid legislation in force related to electrical equipment must be
absolutely followed. The electrical equipment related to a machine conforming to the Machinery Directive must fulfil
the detailed requirements laid down in standard EN 60204-1:2006.
2.2.4.2 Static electricity
The build-up of potentially dangerous electrostatic charges in the machine and its auxiliary equipment must be
prevented or restricted.
2.2.4.3 Errors of fitting
Errors made when fitting parts of the machine can be a source of risk. For this reason, the instructions supplied with
the machine must be absolutely followed during the installation and repairs of the machine.
Faulty liquid and electrical connections can also be a source of risk. With liquid connections, the instructions
supplied with the machine must be followed. Faulty electrical connections must be made impossible by the design,
or information on the risk must be given on cables and connectors.
2.2.4.4 Extreme temperatures
If necessary, the machine must be provided with warnings concerning high surface temperatures. In these cases,
additional steps should be taken to eliminate any risk of injury caused by contact with or proximity to machinery
parts. Maintenance requires the heating of some parts prior to installation. Carefulness is imperative during
installation, and appropriate personal protective equipment must be used during installation.
2.2.4.5 Fire and explosion
Exact and detailed information on the process and the purpose for which the machine is used are essential in terms
of safe operation of the machine. The specific circumstances prevailing at the point of use must always be checked
between the Customer and Manufacturer when the machine is being selected.
With equipment intended for use in potentially explosive atmospheres (ATEX), see section 5 (Ignition hazard
assessment.
2.2.4.6 Noise and vibration
The instructions supplied with the machine provide information on the emission of airborne noise and on the
balancing of rotating parts of the machine. The data given must be taken into account and necessary steps must be
taken in order to eliminate any risks caused by noise or vibration in accordance with the circumstances prevailing at
the point of use.
2.2.4.7 Radiation
The instructions supplied with the machine provide information on the emission of radiation potentially involved in the
measuring equipment of the machine. The operators of the machine must absolutely follow the safety instructions
concerning the use of this equipment.
2.2.4.8 Emissions
The instructions supplied with the machine provide information on the control of leakages in the immediate proximity
of the machine. If necessary, the following steps must be taken to eliminate harmful emissions involved in the
process:

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Safety instructions
account of the emissions and their potential consequences (e.g. possibility of fire, appropriate extinguishing
equipment)
preventing exposure of operators
controlled containment and evacuation of emissions
cleaning of emissions and machinery
appropriate personal protective equipment and warnings
2.2.4.9 Slipping, stumbling and falling
When installing, servicing and repairing the machine, the instructions supplied with the machine, safety instructions
applicable at the point of use and sufficient care and attention must be followed in order to prevent any slipping,
stumbling or falling.
2.2.5 Maintenance
2.2.5.1 Machinery maintenance
The maintenance and repair instructions supplied with the machine must be absolutely followed. The instructions
specify separately which measures require stopping and potential draining of the machine. Appropriate personal
protective equipment as required by the work performed must always be used, e.g.:
hearing protectors
eye protectors
breathing protectors
safety gloves, safety footwear, protective clothing
When servicing and repairing the machine, principles of ergonomics (avoiding excessive use of muscular power,
utilization of lifting gear, lifting positions, lighting of the area, cleanliness etc.) must also be taken into account.
2.2.5.2 Access to operating position and servicing points
Where the location design for the machine is not included in the delivery, steps must be taken to situate the machine
at the point of operation in a manner that enables safe maintenance and repairs of the machine. Provision of
sufficient maintenance space around the machine must be taken into account in the design of the operating
environment.
2.2.5.3 Isolation of energy sources
The controls of the machine must be designed so that they include clearly identified devices that can be used to
isolate the machine from all energy sources. These devices must be capable of being locked if reconnection of
energy could endanger exposed persons. After the energy is cut off, it must be possible to dissipate any energy
remaining or stored in the process (e.g. discharging pressure) without risk to exposed persons.
2.2.5.4 Operator intervention
The controls of the machine must be designed so that the need for operator intervention is limited.
2.2.5.5 Cleaning of (internal) parts of machine
The potential cleaning of the machine must take place in accordance with the instructions supplied with the machine
and the safety instructions applicable at the point of use so that cleaning can be carried out as safely as possible.

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Safety instructions
2.2.6 Indicators
2.2.6.1 Information and warning devices
When designing the controls of the machine, the specified requirements laid down in the Machinery Directive and/or
national legislation of the country where the machine is used must be absolutely followed in terms of information and
warning devices used on the machine.
2.2.6.2 Warning of residual risks
The safety warnings related to the machine must be kept clean under all circumstances, and the warnings must be
renewed when necessary. All operators of the machine must be warned of the residual risks involved in electricity or
the controls in accordance with specified requirements laid down in the Machinery Directive and/or national
legislation of the country where the machine is used.
2.2.6.3 Marking and instructions
The marking and instructions for the machine must be drawn up in accordance with the Machinery Directive and/or
national legislation of the country where the machine is used. Steps must be taken to ensure that the marking and
instructions for other equipment related to a safe use of this machine conform to valid legislation.
In particular, it must be ensured that the point of use is provided with instructions for emergencies, such as:
how to give alarm
location of rescue and fire extinguishing equipment
availability of first aid and necessary first aid equipment
3 Definitions
The following words are used in the instructions to indicate issues which require special attention.
W A R N I N G
There is a risk of personal injury if the instruction is not adhered to.
C A U T I O N
There is a risk of damaging or destroying the product or equipment if the instruction is not adhered to.
N O T E
Is used in the text for highlighting necessary information or requirements which are essential to
observe.

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Safety instructions
4 Essential safety aspects
All of the following relevant safety aspects are to be instructed to the operators and maintenance personnel before
putting the product into service.
General
The product is meant only for the purpose for which it is sold - never operate beyond the intended use
described in these instructions.
Personal injuries may occur if personal protective equipment is not used when servicing the product.
Pump units which convey hazardous media must be decontaminated before beginning any maintenance
work.
If there is a possibility that the pump or the pipeline contains explosive gases or vapours, it must be
ventilated carefully before working on the pump.
If there is a possibility that there are explosive gases or vapours in the atmosphere surrounding the pump,
the pump’s environment must be ventilated carefully before working on the pump.
External heat must not be used when dismantling the pump, as any liquid, gas, vapour or their combination
that remains in the pump may explode.
All safety devices (e.g. coupling and shaft sealing guards) must be correctly installed before starting. For
explosive areas, guards with a non-sparking material are to be used.
Wet end
If there is a possibility of a dangerous return flow after the shutdown of the pump, a nonreturn device shall be
installed in the outlet piping.
The pump must be sufficiently filled with the pumped liquid before starting (with the exception of liquid ring
pumps (-LM, -S), air separating pumps (-R) and pumps equipped with a gas separator (-GM, -GS)).
The pump must run above the minimum recommended flow and never dry (with the exception of liquid ring
pumps (-LM, -S), air separating pumps (-R) and pumps equipped with a gas separator (-GM, -GS)).
The suction valve must be open during operation.
If leakage of harmful or dangerous substances can occur - prepare proper means for a safe waste removal.
The parts in contact with the pumped liquid can be dangerously hot.
Sealing unit
The product must always be equipped with a shaft sealing system compatible with the pumped liquid.
The parts in contact with the pumped liquid can be dangerously hot.
Bearing unit
For delivery, the bearing housing of the pump has been emptied of oil. Remember to refill it before starting.
There is no protection against contact in the shaft seal area.
Drive motor
Always stop the drive unit before beginning any repair work on the pump. Make sure that the motor cannot
be started by any means accidentally during the repairs.
The correct rotating direction of the drive unit must be checked before starting and the pump must rotate
freely (with coupling spacer removed).

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Safety instructions
Coupling unit
The coupling must be properly aligned before starting.
Baseplate
The pump baseplate must be properly installed before starting.
5 Ignition hazard assessment
5.1 General
1 Description of use
Group II category 2 Ex II 2 G c T1, T2, T3 and T4: The equipment is a centrifugal pump designed for use in
environments in which the release of flammable materials will give rise to a zone 1 potentially explosive
atmosphere (zone in which explosive atmospheres caused by mixtures of air and gases, vapours or mists
are likely to occur occasionally during normal operation). The pump is designed for pumping various liquids
in the process industry.
Group II category 3 Ex II 3 G c T1, T2, T3 and T4: The equipment is a centrifugal pump designed for use in
environments in which the release of flammable materials will give rise to a zone 2 potentially explosive
atmosphere (zone in which explosive atmospheres caused by mixtures of air and gases, vapours or mists
are likely to occur occasionally during normal operation). The pump is designed for pumping various liquids
in the process industry.
2 Construction
The pump is horizontally mounted and has a single-stage end-suction design. The pump shaft is mounted on
antifriction bearings so that the bearing at the impeller end carries radial loads, while the bearings at the
clutch end carry mainly axial loads. The pump is made from cast iron (for non-corroding liquids) or acid-
resistant steel (for corroding liquids). The pump easily passes the required mechanical tests described in EN
13463-1. There are no light metal or plastic parts that need consideration, or other relevant restrictions as
described in EN 13463-1.
The pump’s design is such that it will not leak even in the event of a foreseeable malfunction. In normal
operation, the pump contains the liquid being pumped. In a self-priming design, the pump is filled with air or
a mixture of air and, for example, vapours or mists when the pump starts and before it is filled with the liquid
that is to be pumped. This is a planned function and does not compromise the functioning of the pump. The
pump is sealed either by a single-acting or double-acting slide ring seal or a dynamic seal, depending on the
operating conditions. If a slide ring seal is used, the sliding faces are lubricated by either the liquid that is
being pumped or an external sealing liquid.
The pump mounting has been designed to withstand the expected loads and vibration caused by the pump.
The installation, operation and maintenance instructions include details of the support required by the pipes.
3 Ignition hazard assessment
The ignition hazard assessment according to 5.2 of EN 13463-1 + AC identifies that, because of its
construction and on the basis of testing (temperature classification and shock resistance tests), no ignition
sources exist in normal operation, during scheduled maintenance or repairs.
The table below lists all potential ignition sources that can be detected on the basis of experience, assesses
the measures applied to prevent the source becoming effective and specifies the ignition protection methods
used. This ignition hazard assessment document is placed in the manufacturer’s technical file.

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Safety instructions
4 Marking with regard to ignition protection
EN 13463-1 requires the equipment to be marked with the symbol(s) of the ignition protection used. In this
particular case, the pump complies with EN 13463-1 and EN 13463-5 and the symbol ’c’ will therefore be
included in the marking.
5.2 Group II category 2 (Ex II 2 G c T1, T2, T3 and T4)
Potential ignition source (1) Measures applied to prevent the
source becoming effective (2)
Ignition
protection used
Normal
operation (1a)
Expected
malfunction (1b)
Rare malfunction
(1c)
Assembly
Electrostatic
discharge from
the pump’s
external
surfaces and
subsequent
arcing
Electrostatic charging is not possible, as
the pump has no exposed plastic parts.
Metal parts are attached to each other so
that there are no differences in potential.
There is no ignition source.
EN 13463-1 + AC
7.4
EN 13463-1 + AC
11.
EN 13463-5 ’c’
The pump is
driven at excess
speed and is
therefore
damaged.
The design rotation speed for the pump is
indicated on a label attached to the pump
body.
EN 13463-5 ’c’
Accumulation of
an explosive
mixture of gases
or air in the
pump
All air or gas mixtures are discharged
from the pump when liquid enters.
The pump is so designed that gases or
air cannot accumulate outside the pump.
There is no ignition source.
EN 13463-1 + AC
15.
EN 13463-5 ’c’
IOM
The clutch cover
makes contact
with the clutch
and causes
frictional arcing
or heat
The clutch cover is designed so that
there is sufficient clearance to prevent
contact between the rotating clutch and
the clutch cover.
There is no ignition source.
EN 13463-5 ’c’
The clutch cover
is deformed
because of a
shock so that the
clutch makes
contact with the
clutch cover,
which causes
frictional heat or
arcing.
The strength of the clutch cover has been
checked by shock resistance tests.
There is no ignition source.
EN 13463-1 + AC
13.3.2
Clutch The clutch is
aligned or
installed
incorrectly, which
leads to clutch
breakage and
arcing.
Clutch breakage
because of a rare
malfunction, such
as jamming, a
material defect in
the clutch or
excessive pipe
strain on the pump.
Not considered.
The installation, operation and
maintenance manual contains
instructions on the installation and
alignment of the clutch.
There is no ignition source.
EN 13463-5 ’c’ 8
IOM

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ORIGINAL INSTRUCTION
USER'S MANUAL – AHLSTAR
Safety instructions
Potential ignition source (1) Measures applied to prevent the
source becoming effective (2)
Ignition
protection used
Normal
operation (1a)
Expected
malfunction (1b)
Rare malfunction
(1c)
Bearings
Overheating of
bearings
A bearing breaks
and overheats
The bearings are dimensioned for
continuous operation at rated values. The
installation, operation and maintenance
manual contains instructions on the
maintenance and condition monitoring of
bearings. The pump has vibration
measurement fittings through which the
condition of the bearings can be
monitored.
There is no ignition source.
EN 13463-5 ’c’ 6
IOM
Insufficient
lubrication of
bearings, which
leads to their
overheating
Oil-lubricated bearings have a sight glass
for monitoring the oil level.
The installation, operation and
maintenance manual contains
instructions on the lubrication of bearings.
There is no ignition source.
EN 13463-5 ’c’ 6
IOM
Overheating of
grease-lubricated
bearings because
of excessive
grease
The installation, operation and
maintenance manual contains
instructions on correct lubrication to
prevent the overheating of bearings.
There is no ignition source.
EN 13463-5 ’c’ 6
IOM
Ingress of water or
other impurities into
the bearings, which
leads to insufficient
lubrication, bearing
failure and the
overheating of
bearings
The installation, operation and
maintenance manual contains
instructions on the maintenance and
condition monitoring of bearings. Failure
caused by the ingress of water is shown
as increased vibration of the bearings,
which can be detected during condition
monitoring. The pump has vibration
measurement fittings through which the
condition of the bearings can be
monitored.
There is no ignition source.
EN 13463-5 ’c’ 6
IOM
The metal part of
the bearing’s
rotating ring rubs
against the labyrinth
static seal and arcs
or overheats; a
shock on a metal
part deforms the
rotating ring.
The rotating ring is protected with the
shock-resistant clutch cover at the drive
end. The rotating ring at the impeller end
is located inside a socket, which is
extremely unlikely to be subjected to
shocks.
Does not apply to categories 2 and 3.
There is no ignition source.
EN 13463-5 ’c’
Rotary shaft seals
Failure of the
sealing face of a
mechanical seal
lubricated with the
liquid being
pumped due to
insufficient
lubrication, which
leads to seal
overheating.
Rotary shaft seals must always be
selected on a case-by-case basis,
depending on the liquid to be pumped
and process conditions. The installation,
operation and maintenance manual
contains instructions on the condition
monitoring of seals.
There is no ignition source.
EN 13463-1 + AC
15.
EN 13463-5 ’c’
IOM